System Overview
This section of the manual provides an overview of the Power Hive components.
Diagrams and Terminology
PowerHive Overview
Figure 2: PowerHive Robot Cell (1-Rack System) (Some Items Hidden for Clarity)
Rack 1 (Primary Rack) – This rack is required for every PowerHive system and includes a unique High Voltage panel for powering the robot, as well as the main Low Voltage panel and operator interface (HMI).
Secondary Racks (1, 2, 4 and 5) – These racks can be added at various positions alongside the Primary Rack to increase system capacity.
Robot Mounting Plate – Mounted to the floor to serve as a rigid, flat surface for the robot.
Robot – Moves batteries from racks to forklifts.
Robot Safety Fencing – Acts a physical barrier around the robot and prevents people from inadvertently entering the PowerHive cell.
Figure 3: PowerHive Robot Cell, Cont.
Hallway Safety Fencing – Acts as a physical barrier to establish the outside edge of the forklift hallway and provides mounting locations for the hallway light curtains. In some instances, this section of fencing can be omitted in place of an actual building wall.
Base of Arm (BOA) Camera – Located at the base of the robot facing the hallway, this camera detects forklifts entering the hallway to prepare for battery swap process.
Pressure Pad - A black mat that detects the presence of an operator. Operators must remain on the pressure pad throughout the entirety of a swap.
HMI Screen and Main Low Voltage Box – The low voltage box is located on the side of rack 1. This acts as 24V distribution for the system as well as the location of the safety controllers. The HMI is located on the front door of the LV box and acts as the operator interface for the PowerHive.
Figure 4: Light Curtains (Red depicts light path)
Robot Light Curtain – Detects motion along the robot opening of the PowerHive Cell. Acts as emergency stop if an object passes through the plane of the curtain.
Hallway Light Curtains – Detects motion at the entry and exit (front and back) of the PowerHive Forklift Hallway. Stops robot motion if an object passes through the plane of either
curtain during a battery swap process. Disabled when not actively swapping a battery to allow forklifts and operators to enter and exit before and after the swap process.
Figure 5: Floor Scanner Locations (Red depicts coverage area)
Floor Scanners – Two scanner heads, one at the base of rack 1 and the other on the opposite side of the robot, detects motion inside of the PowerHive Cell. Acts as emergency stop if an unknown object is detected inside of the cell.
High Voltage Box – Each rack includes a high voltage box that acts as 480V distribution to the battery chargers. The high voltage box on rack 1 includes the main 24V supply for the system and also provides power to the robot.
Figure 6: System Components
Hallway Camera – Located along the outer fencing as you enter the forklift hallway, this camera is positioned to detect people inside of the hallway that may be hidden by the forklift from the operator at the initiation of the battery swap process. If a person is detected, it will alert the operator to confirm the hallway is clear again before continuing swap process.
System Health Light Tower – A red/amber/green light tower mounted at the entry of the PowerHive hallway provides a visual indicator of the health of the system.
Parking Assist Light – Provides a visual indicator to the forklift operator when to stop the forklift within the hallway for optimal robot access to the battery.
External Emergency Stop Button – Stops all system motion if pressed.
Figure 7: PowerHive Red Lights (red areas depict light path)
Hallway Red Light – Mounted inside the PowerHive cell at the entry and exit (front and back) of the PowerHive hallway, this light emits a red beam along the light curtain path to alert bystanders that the hallway light curtains are active. If the light curtain is broken or tripped, the system will stop, and the red light will flash until the system fault is cleared via the HMI.
Robot Red Light – Mounted inside the PowerHive cell at robot opening, this light emits a red beam along the light curtain path to alert bystanders that the robot light curtain is active. If the light curtain is broken or tripped, the system will stop, and the red light will flash until the system fault is cleared via the HMI.
Figure 8: Floor Markings
Operator Walkway – Solid yellow tape on the floor acts a dedicated operator walkway from the forklift to the PowerHive HMI screen.
Forklift Lane – White and black striped tape on the floor acts a dedicated driving lane for the forklift to enter the PowerHive hallway.
Light Curtain Caution Tape – Yellow and black striped tape on the floor acts a visual indicator of the light curtain path for people near the PowerHive.
Hallway Protection Devices Overview
Figure 9: Hallway Protections
Post Protector – Located around fence posts vulnerable to forklift damage.
Panel Protector – Long, straight, protectors along fencing to prevent forklifts from scrubbing along fence panels.
Clear Light Curtain Cover – Tall, clear covers mounted beside hallway light curtains to prevent bumping the curtains out of alignment.
Safety Bollard – 36” tall round post used to protect critical areas.
Optional Customer-Supplied Protection
Figure 10 provides information on optional customer-supplied supplementary protection locations around the PowerHive as needed.
Figure 10: Suggested Supplemental Protection Areas
PowerHive Configurations
There are multiple PowerHive rack configurations. It is important to understand which configuration is being installed before mounting any components, as overall dimensions will change. See configuration images below:
Provide System Config Images of Different Rack Layouts