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Subsystem Descriptions

Cradle Subsystem​

The cradle houses the battery and facilitates seamless interactions with the forklift and RoboSwap System.

Components:​

  • BDI: Battery Discharge Indicator is located on the vehicle and displays State of Charge information to the operator.

  • Brush Assembly / NFC System: Conducts power from the battery to the vehicle and enables data exchange between the cradle, battery, and racks.

  • Backup Battery: Powers auxiliary loads during battery exchanges.

  • External Interface: Used to start, stop, and autodisable the cradle during reloads.

  • Power Connection: Primary power connection and BDI interface location. Bolted connection for heavy-gauge wiring to the forklift.

Operations:​

  • Cradle retention brackets secure the battery during operation.

  • Power terminals and communication interface facilitate real-time power and data transfer.

  • The cradle interfaces with the robot to ensure precise battery positioning.

Battery Subsystem​

Batteries are the core energy storage units, designed for durability and reliability. All batteries comply with UN 38.3 and UN 3090 standards. Standard size batteries are UL 2580 certified with plans to certify XL packs in 2025.

All batteries are designed to operate with any cradle as much as possible. With some caveats, batteries can be interchanged between cradles as desired. The system loads a battery of the extracted type when a reload is requested.

Battery Size – Standard:​

Standard batteries are typically used for lighter-duty applications or smaller forklifts. Standard and XL batteries can be mixed in the fleet, but a cradle is configured to only use one type at a time.

24V batteries only come in “Standard” size due to their high Ah capacity in the form factor.

  • 24V 480Ah (25.9V nominal)

  • 36V 480Ah (37.0V nominal)

Battery Size – XL:​

XL batteries are typically used for larger vehicles or longer duration runtime between reloads. The pack is approximately 5.5” longer than the Standard battery.

  • 36V 672Ah (37.0V nominal)

  • 48V 480Ah (51.8V nominal)

Features:​

  • Built-in safety measures (BMS), such as thermal management and low-SOC shutdown.

  • Specialized contact plates for power transfer

  • Short-range wireless NFC communication to cradles and charging sleeves.

  • Machine vision during reload used for remote-tracking and operational identification.

Operations:​

  • Batteries are tracked via DM codes and monitored for state of charge (SOC), temperature, cycle count, cell voltages, Ah throughput, faults, and other pertinent operational and safety data.

  • During operation, batteries interface with the cradle in the vehicle and charging sleeves while in the racks for charging or storage.

Telemetry System​

The telemetry system provides real-time monitoring and logging of operational data.

Components:​

  • HMI: A touch interface for operators to interact with the system as needed.

    • Used to inform the operator of the status of the reload and Hive.

    • Can be used by the technician to reset application processes and visualize the state of the batteries in the racks.

  • Communication: Ethernet IP and Modbus communication over Ethernet Cat6 cabling with n

  • Wi-Fi networks.

    • A cellular uplink transmits aggregated data to offsite data servers.

  • Cradle Controller: Gathers operational vehicle data and stores on the battery controller for upload after returning to the Hive.

  • Battery Controller: Stores data for upload to the Hive.

Functions:​

  • Tracks battery health, charging cycles, rack activity, and records vehicle and battery discharge events.

  • Logs operational data for troubleshooting and performance optimization.

  • Alerts operators to faults or maintenance needs.

Rack Subsystem​

Racks provide storage and charging for batteries and act as critical infrastructure for the system.

Features:​

  • Charging bays with integrated brush assemblies – similar to the assemblies in the cradle.

  • Magnetic, safety-rated door locks to secure batteries and prevent unauthorized access.

  • Modular design to support multiple racks for scalability.

Operations:​

  • Racks interface with the robot for battery placement and retrieval.

  • Chargers within racks maintain optimal battery performance.

Robot Subsystem​

The Kawasaki BX300L robotic arm manages battery movement and operates using command instructions from the PC in the LV Cabinet.

Features:​

  • End of Arm Tool (EoAT): Includes a mechanical gripper, camera, laser line profile scanner, ToF laser sensor, and safety sensors for detection of a battery in the gripper.

  • Robot Controller: Kawasaki Robotics E0x controller is used for motion control and application software interface.

  • Cubic-S integrated safety controller for enforcing safe zones.

    • Separate processor/controller but integrated int

  • Robot Controller housing.

    • o Primary external interface with E-Stop circuit and Reer Safety System Controller.

    • Internal connection t

  • E0x controller I/O and joint encoders.

Operations:​

  • The robot executes battery swaps, moving batteries between cradles, racks, and charging stations.

  • Safety measures ensure the robot halts immediately upon detecting an intrusion.