Systems and methods for a battery panel assembly on a material handling vehicle

A battery panel assembly for a material handling vehicle having a battery is provided. The battery panel assembly includes an inner counterweight panel configured to couple to the battery assembly. The inner panel including a battery service cutout. The battery panel assembly further includes an outer panel configured to couple to the inner panel. The outer panel includes a cutout configured to align with the battery service cutout and an access door dimensioned to cover the cutout.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND

In general, material handling vehicles may include a battery. The battery may be a lithium-ion battery and may be housed in a battery compartment. The compartment may have a cover to protect the battery from environmental factors.

BRIEF SUMMARY

The present disclosure relates generally to a material handling vehicle, and, more specifically, systems and methods to enclose a compartment on the material handling vehicle to protect a battery from environmental factors. Additionally, the present disclosure relates to battery enclosure systems and methods that can add counterweight to the material handling vehicle.

In one aspect, the present disclosure provides a battery panel assembly for a material handling vehicle having a battery assembly. The battery panel assembly includes an inner counterweight panel configured to couple to the battery assembly. The inner panel including a battery service cutout. The battery panel assembly further includes an outer panel configured to couple to the inner panel. The outer panel includes a cutout configured to align with the battery service cutout, and an access door dimensioned to cover the cutout.

In one aspect, the present disclosure provides a battery panel assembly for a material handling vehicle having a battery compartment with a battery assembly. The battery compartment includes a left side and a right side. The battery panel assembly includes a right inner panel configured to couple to the right side of the battery compartment and a right outer panel configured to couple to the right inner panel. The right inner panel includes a first battery access cutout. The right outer panel includes a first opening in alignment with the first cutout and an access door dimensioned to cover the first opening. The battery panel assembly further includes a left inner panel configured to couple to the left side of the battery compartment and a left outer panel configured to couple to the left inner panel. The left inner panel includes a second battery access cutout. The left outer panel includes a second opening in alignment with the second battery access cutout and an access panel configured to cover the second opening.

In one aspect, the present disclosure provides a method for adding counterweight to a battery assembly on a material handling vehicle. The method includes coupling a first inner panel to a first side of the battery assembly, thereby adding counterweight to the battery assembly, and coupling a first outer panel to the first inner panel to enclose the battery assembly.

The foregoing and other aspects and advantages of the disclosure will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred configuration of the disclosure. Such configuration does not necessarily represent the full scope of the disclosure, however, and reference is made therefore to the claims and herein for interpreting the scope of the disclosure.

DETAILED DESCRIPTION

Also as used herein, unless otherwise specified or limited, directional terms are presented only with regard to the particular embodiment and perspective described. For example, reference to features or directions as “horizontal,” “vertical,” “front,” “rear,” “left,” “right,” and so on are generally made with reference to a particular figure or example and are not necessarily indicative of an absolute orientation or direction. However, relative directional terms for a particular embodiment may generally apply to alternative orientations of that embodiment. For example, “front” and “rear” directions or features (or “right” and “left” directions or features, and so on) may be generally understood to indicate relatively opposite directions or features.

Also as used herein, ordinal numbers are used for convenience of presentation only and are generally presented in an order that corresponds to the order in which particular features are introduced in the relevant discussion. Accordingly, for example, a “first” feature may not necessarily have any required structural or sequential relationship to a “second” feature, and so on. Further, similar features may be referred to in different portions of the discussion by different ordinal numbers. For example, a particular feature may be referred to in some discussion as a “first” feature, while a similar or substantially identical feature may be referred to in other discussion as a “third” feature, and so on.

Generally, the present disclosure provides a battery panel assembly including a right battery panel assembly and a left battery panel assembly configured for a material handling vehicle. The right battery panel assembly and the left battery panel assembly may enclose a battery compartment on the material handling vehicle and protect a battery within the battery compartment from environmental factors. In one non-limiting example, the battery may be a lithium-ion battery. Additionally, the battery panel assembly may act as a vehicle counterweight while providing for installation and alignment of a multi-layered cover over a battery compartment opening.

A battery panel assembly according to the present disclosure may include a first or right assembly and a second or left assembly.FIG. 1illustrates one non-limiting example of a first or right battery panel assembly100according to one aspect of the present disclosure. The right battery panel assembly100may be configured to engage one side (e.g., a right side) of a battery compartment50on a material handling vehicle60. The battery compartment50may house a battery assembly70and counterweight assembly80. The right battery panel assembly100may include a right inner panel102and a right outer panel104. When assembled, the right battery panel assembly100may be configured to cover a right opening106of the battery compartment50(see, e.g.,FIG. 2).

As shown inFIG. 1, the right inner panel102may be configured to be removably coupled to the battery assembly70. Additionally or alternatively, the right inner panel102may be coupled to any combination of the battery compartment50, material handling vehicle60, or the counterweight assembly80. The right outer panel104may be removably coupled to the right inner panel102. Similar to the right inner panel102, the right outer panel104may be additionally or alternatively coupled to any combination of the battery compartment50, material handling vehicle60, the battery assembly70, or the counterweight assembly80. In another non-limiting example, the right battery panel assembly100may include a single panel, however other configurations are possible. For example, the right battery panel assembly100may include more than two panels.

The right inner panel102of the right battery panel assembly100can include a top portion108and a bottom portion110. The top portion108of the right inner panel102may include at least one keyhole slot112. In the illustrated non-limiting example, the top portion108of the right inner panel102may include a pair of keyhole slots112that are laterally separated from one another. Each of the keyhole slots112may be configured to receive a fastener114, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In another non-limiting example, the right inner panel102may include more or less than two of keyhole slots112on the top portion108and/or the bottom portion110, which may be configured to receive a corresponding number of fasteners. The plurality of keyhole slots112, for example, may be configured to engage a protrusion, which facilitates securing and aligning the right inner panel102to the material handling vehicle60or the battery assembly70.

The top portion108of the right inner panel102may include one or more fastening apertures115and a battery service cutout116dimensioned to allow a charger (not shown) to access a battery mounted charging connector118on the battery assembly70, when the right battery panel assembly100is assembled and covering the right opening106of the battery compartment50. In another non-limiting example, the battery service cutout116may include a removable cover. The removable cover, for example, may be removably coupled or hingedly connected to the right inner panel102to provide access to the battery mounted charging connector118.

The bottom portion110of the right inner panel102may include an inner panel inspection hole120dimensioned to provide visual access to a battery retaining pin122to see that the battery assembly70has been secured to the counterweight assembly80. The battery retaining pin122may be inserted through holes in the counterweight assembly80and the battery assembly70, and may be retained by a pin. The bottom portion110of the right inner panel102may further include one or more clearance holes124. In the illustrated non-limiting example, the bottom portion110includes two clearance holes124that are laterally separated from one another. Each of the clearance holes124may be configured to receive a fastener126, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In another non-limiting example, the right inner panel102may include a plurality of clearance holes in the top portion108and/or the bottom portion110each configured to receive a fastener.

Additionally, the bottom portion110of the right inner panel102may include a notch127that facilitates lifting and removal of the right inner panel102from the material handling vehicle60. In some applications, the notch127may provide access to a remote grease fitting (not shown) on the material handling vehicle60. In the illustrated non-limiting example ofFIG. 1, the notch127may be arranged along a bottom surface or edge of the bottom portion110of the right inner panel102, however, other configurations are possible. For example, the notch127may be on any of the sides of the right inner panel102or may be a through hole on a surface of the right inner panel102.

The right outer panel104of the right battery panel assembly100may include a top portion128, a bottom portion130, and a right edge132. The top portion128of the right outer panel104may include at least one clearance hole134. In the illustrated non-limiting example, the top portion128of the right outer panel104includes two clearance holes134that are laterally separated from one another. Each of the clearance holes134may be configured to receive a fastener136, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In another non-limiting example, the right outer panel104may include a plurality of clearance holes in the top portion128and/or the bottom portion130each configured to receive a fastener. Further, the top portion128may include a charge connector access door138. The charge connector access door138may be hingedly connected or removably coupled to the right outer panel104. The charge connector access door138may cover a cutout140dimensioned to allow the charger to access the battery mounted charging connector118on the battery assembly70when the right battery panel assembly100is fully assembled and covering the right opening106of the battery compartment50. In other words, the cutout140is configured to align with the battery service cutout116.

The bottom portion130of the right outer panel104may include at least one keyhole144. In the illustrated non-limiting example, the bottom portion130of the right outer panel104may include two keyholes144that are laterally separated from one another. Each of the keyholes144may be configured to receive a fastener146, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In the illustrated non-limiting example, the keyholes144may be configured to engage the fasteners146, which are configured as a protrusion from the right inner panel102. In another non-limiting example, the right outer panel104may include a plurality of keyhole slots on the top portion128and/or the bottom portion130each configured to receive a fastener.

The bottom portion130of the right outer panel104may further include a lifting hole152that may facilitate the installation and removal of the right outer panel104to the material handling vehicle60. In the illustrated non-limiting example ofFIG. 1, the lifting hole152may be substantially centered in the bottom portion130of the right outer panel104, however, other configurations are possible. For example, the lifting hole152may be located at various locations along the top portion128or the bottom portion130of the right outer panel104. The lifting hole152may alternatively be configured as a notch similar to notch127in the right inner panel102. In some applications, the lifting hole152may provide access to a remote grease fitting (not shown) on the material handling vehicle60.

The bottom portion130of the right outer panel104may further include an outer panel inspection hole154that aligns with the inspection hole120on the right inner panel102, which may provide visual access to the battery retaining pin122to see that the battery assembly70has been secured to the counterweight assembly80.

The right edge132of the right outer panel104may include a sensor target bracket156. The sensor target bracket156may be used to verify that the right battery panel assembly100has been installed before operation of the material handling vehicle60. The sensor target bracket156may be detected by a sensor on the material handling vehicle60. In other non-limiting examples, the sensor target bracket156may be located on any of the sides of the right outer panel104.

To assemble the first or right battery panel assembly100, the right inner panel102may initially be coupled to one side of the battery assembly70. For example, the right inner panel102may be installed onto one side of the battery assembly70, such that the fasteners114extend through the keyhole slots112. With the fasteners114installed within the keyhole slots112, the right inner panel102may be supported on the side of the battery assembly70. The fasteners126may then be inserted through the clearance holes124and be fastened to, for example, a threaded aperture on the side of the battery assembly70to fasten the right inner panel102to the battery assembly70.

With the right inner panel102installed onto the battery assembly70, the right outer panel104may be installed onto the right inner panel102, thereby covering the right opening106and substantially enclosing the side of the battery assembly70. For example, the right outer panel104may be installed onto the right inner panel102, such that the fasteners146extend through the keyholes144. With the fasteners146installed within the keyholes144, the right outer panel104may be supported on the right inner panel102. The fasteners136may then be inserted through the clearance holes134and be fastened to the fastening apertures115on the right inner panel102to fasten the right outer panel104to the right inner panel102.

During assembly, the notch127and the lifting hole152may be used to support the right inner panel102and the right outer panel104, respectively. For example, a crane, a lift, a jack, or another form of support may be coupled to the notch127and the lifting hole152during assembly.

As illustrated inFIG. 2, when the first or right battery panel assembly100is installed onto the battery assembly70, the right outer panel104is generally received within the right opening106to enclose the battery assembly70. In general, the right inner panel102may weigh more than the right outer panel104, for example, due to the right inner panel102being fabricated from a material with a higher density. In this way, for example, the right inner panel102may serve as an additional counterweight. In one non-limiting example, the right inner panel102may be fabricated from a steel material, however, other materials are possible. For example, the right inner panel102may be fabricated from ductile iron. The weight of the right inner panel102may be varied by adding or removing material to the right inner panel102to add weight to the material handling vehicle60. The right inner panel102may also provide additional protection to the battery assembly70.

In one non-limiting example, the right outer panel104may be fabricated from a steel material, however, other configurations are possible. For example, the right outer panel104may be fabricated from a relatively lighter weight material such as aluminum or plastic. The right outer panel104may provide the battery compartment50with additional protection for the battery assembly70of the material handling vehicle60. In addition, the right outer panel104may selectively provide access to components of the battery assembly70, as needed. For example, the access door138may be manipulated to selectively provide access to the battery mounted charging connector118.

FIG. 3illustrates a non-limiting example of a second or left battery panel assembly200according to one aspect of the present disclosure. The left battery panel assembly200is configured to engage one side (e.g., a left side) of the battery compartment50on the material handling vehicle60. The left battery panel assembly200may include a second or left inner panel202and a second or left outer panel204. The left battery panel assembly200may be configured to cover a second left opening206of a battery compartment50on a material handling vehicle60.

As shown inFIG. 3, the left inner panel202may be configured to be removably coupled to the battery assembly70. Additionally or alternatively, the left inner panel202may be coupled to any combination of the battery compartment50, material handling vehicle60, or the counterweight assembly80. The left outer panel204may be removably coupled to the left inner panel202. Similar to the left inner panel202, the left outer panel204may be additionally or alternatively coupled to any combination of the battery compartment50, material handling vehicle60, the battery assembly70, or the counterweight assembly80. In another non-limiting example, the left battery panel assembly200may include a single panel, however other configurations are possible. For example, the left battery panel assembly200may include more than two panels.

The left inner panel202of the left battery panel assembly200can include a top portion208and a bottom portion210. The top portion208of the left inner panel202may include at least one keyhole slot212. In the illustrated non-limiting example, the top portion208of the left inner panel202may include a pair of keyhole slots212that are laterally separated from one another. Each of the keyhole slot212may be configured to receive a fastener214, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In another non-limiting example, the left inner panel202may include a more or less than two keyhole slots212on the top portion208and/or the bottom portion210, which may be configured to receive a corresponding number of fasteners. The plurality of keyhole slots212, for example, may be configured to engage a protrusion that facilitates securing and aligning the left inner panel202to the material handling vehicle60or the battery assembly70.

The top portion208of the left inner panel202may include one or more fastening apertures215arranged laterally outwardly relative to the keyhole slots212and a battery service cutout216. The battery service cutout216may be dimensioned to allow access to a display218and service ports219on the battery assembly70, when the left battery panel assembly200is fully assembled and covering the left opening206of the battery compartment50. In another non-limiting example, the battery service cutout216may include a removable cover. The removable cover, for example, may be removably coupled or hingedly connected to the left inner panel202to provide access to the display218and service ports219on the battery assembly70.

The bottom portion210of the left inner panel202may include an inner panel inspection hole (not shown) dimensioned to allow a battery retaining pin (not shown) to pass through. The bottom portion210of the left inner panel202may further include at least one clearance hole224. In the illustrated non-limiting example, the bottom portion210includes two clearance holes224that are laterally separated from one another. Each of the clearance hole224may be configured to receive a fastener226, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In another non-limiting example, the left inner panel202may include a plurality of clearance holes in the top portion208and/or the bottom portion210each configured to receive a fastener.

Additionally, the bottom portion210of the left inner panel202may include a notch227that facilitates lifting and removal of the left inner panel202from the material handling vehicle60. In the illustrated non-limiting example ofFIG. 3, the notch227may be arranged along a bottom surface or edge of the bottom portion210of the left inner panel202, however, other configurations are possible. For example, the notch227may be on any of the sides of the left inner panel202or may be a through hole on a surface of the left inner panel202.

The left outer panel204of the left battery panel assembly200may include a top portion228, a bottom portion230, and a left edge232. The top portion228of the left outer panel204may include at least one clearance hole234. In the illustrated non-limiting example, the top portion228of the left outer panel204includes two clearance holes234that are laterally separated from one another. Each of the clearance holes234may be configured to receive a fastener236, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In another non-limiting example, the left outer panel204may include a plurality of clearance holes in the top portion228and/or the bottom portion230each configured to receive a fastener.

The top portion228may include an access panel238. The access panel238may have at least one mounting hole242to receive at least one fastener243. In the illustrated non-limiting example, the access panel238includes two mounting holes242that are laterally separated from one another and each configured to receive a fastener243. The access panel238may be removably coupled to the left outer panel204via the fasteners243. The access panel238may cover a cutout240on the top portion228. The cutout240may be configured to selectively provide access to the display218and the service ports219on the battery assembly70, when the left battery panel assembly200is fully assembled. In other words, the cutout240is configured to align with the battery service cutout216and may be selectively removed from the left outer panel204. In another non-limiting example, the access panel238may be hingedly or slidably coupled to the left outer panel204.

The bottom portion230of the left outer panel204may include at least one keyhole244. In the illustrated non-limiting example, the bottom portion230of the left outer panel204may include two keyholes244that are laterally separated from one another. Each of the keyholes244may be configured to receive a fastener246, which can be a screw, pin, rod, or any other suitable type of mounting hardware. In the illustrated non-limiting example, the keyholes244are configured to engage the fasteners246, which are configured as a protrusion from the left inner panel202. In another non-limiting example, the left outer panel204may include a plurality of keyhole slots on the top portion228and/or the bottom portion230each configured to receive a fastener.

The bottom portion230of the left outer panel204may further include a lifting hole252that may facilitate the installation and removal of the left outer panel204to the material handling vehicle60. In the illustrated non-limiting example ofFIG. 3, the lifting hole252may be substantially centered in the bottom portion230of the left outer panel204, however, other configurations are possible. For example, the lifting hole252may be located at various locations along the top portion228or the bottom portion230of the left outer panel204. The lifting hole252may alternatively be configured as a notch similar to notch227in the left inner panel202.

The left edge232of the left outer panel204may include a sensor target bracket256. The sensor target bracket256may be used to verify that the left battery panel assembly200is installed before operation of the material handling vehicle60. The sensor target bracket256may be detected by a sensor on the material handling vehicle60. In other non-limiting examples, the sensor target bracket256may be located on any of the sides of the left outer panel204.

To assemble the second or left battery panel assembly200, the left inner panel202may initially be coupled to one side of the battery assembly70. For example, the left inner panel202may be installed onto one side of the battery assembly70, such that the fasteners214extend through the keyhole slots212. With the fasteners214installed within the keyhole slots212, the left inner panel202may be supported on the side of the battery assembly70. The fasteners226may then be inserted through the clearance holes224and be fastened to, for example, a threaded aperture on the side of the battery assembly70to fasten the left inner panel202to the battery assembly70.

With the left inner panel202installed onto the battery assembly70, the left outer panel204may be installed onto the left inner panel202, thereby covering the left opening206and substantially enclosing the side of the battery assembly70. For example, the left outer panel204may be installed onto the left inner panel202, such that the fasteners246extend through the keyholes244. With the fasteners246installed within the keyholes244, the left outer panel204may be supported on the left inner panel202. The fasteners236may then be inserted through the clearance holes234and be fastened to the fastening apertures215on the left inner panel202to fasten the left outer panel204to the left inner panel202.

During assembly, the notch227and the lifting hole252may be used to support the left inner panel202and the left outer panel204, respectively. For example, a crane, a lift, a jack, or another form of support may be coupled to the notch227and the lifting hole252during assembly.

As illustrated inFIG. 4, when the second or left battery panel assembly200is installed onto the battery assembly70, the left outer panel204is generally received within the left opening206to enclose the battery assembly70. In general, the left inner panel202may weigh more than the left outer panel204, for example, due to the left inner panel202being fabricated from a material with a higher density. In this way, for example, the left inner panel202may serve as an additional counterweight. In one non-limiting example, the left inner panel202may be fabricated from a steel material, however, other materials are possible. For example, the left inner panel202may be fabricated from ductile iron. The weight of the left inner panel202may be varied by adding or removing material to the left inner panel202to add weight to the material handling vehicle60. The left inner panel202may also provide additional protection to the battery assembly70.

In one non-limiting example, the left outer panel204may be fabricated from a steel material, however, other configurations are possible. For example, the left outer panel204may be fabricated from a relatively lighter weight material such as aluminum or plastic. The left outer panel204may provide the battery compartment50with additional protection for the battery assembly70of the material handling vehicle60. In addition, the left outer panel204may selectively provide access to components of the battery assembly70, as needed. For example, the access panel238may be selectively removed to provide access to the display218and the service ports219.

It is to be appreciated that each of the inner panels and outer panels can be made of various materials. For example, the inner panels can be a casting of steel or ductile iron, as non-limiting examples. The outer panels can be a lighter weight material. For example, the outer panels can be made from aluminum or plastic, as non-limiting examples.

Thus, while the invention has been described in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein.