Abstract: A mechanical stabilization system for a battery assembly is disclosed. The system includes an actuator and a stabilizer that are configured to work in concert. The actuator and stabilizer are disposed in a housing of the battery assembly. The system may be implemented by depression of the actuator disposed in the housing, which causes the stabilizer to retract a support post into the housing. The depression can occur during a docking operation of the battery assembly with a lift mechanism for an electric vehicle. When the actuator is released, the support post automatically reverts to its previous, deployed state. The support post is configured to maintain the battery assembly in a stable configuration when the battery assembly is separated from the electric vehicle.

Abstract: An automated connection and disconnection system for a battery assembly is disclosed. The system may be implemented by a first component of an electric vehicle and a second component of the battery assembly. The first component includes a linear actuator that is configured to push a set of electrical connectors associated with the electric vehicle outward and establish a connection with a corresponding set of electrical connectors associated with the battery assembly. The process of connecting or docking the battery assembly to the electric vehicle is thereby automated and the time needed to exchange batteries is reduced. The system further includes provisions for ensuring the two components remain aligned relative to one another during docking.

Abstract: An electric power distribution system and method for an electric mining machine is described. In one embodiment, a method for electric power distribution includes receiving information associated with a state of charge of a first battery pack that supplies electric power to a front electric motor configured to drive a front axle of an electric mining machine. The method also includes receiving information associated with a state of charge of a second battery pack that supplies electric power to a rear electric motor configured to drive a rear axle of the electric mining machine. The method includes comparing the state of charge of the first battery pack and the second battery pack and, upon determining that the state of charge of the second battery pack is greater than the state of charge of the first battery pack, increasing electric power to the rear electric motor of the electric mining machine.

Abstract: A method for assembling a battery module including a unified connection array with a flexible connector is described. The flexible connector can include a plurality of pads that are secured to a central spine. The flexible connector may be a single piece connector. The flexible connector can include monitors that are mounted to the flexible connector to gather data regarding battery cells of the battery module.

Abstract: The disclosed battery management system generally includes at least one bi-directional balancing circuit and a power supply including a first battery module and a second battery module, each having at least one battery cell. The balancing circuit may be configured to transfer excess charge from one or more battery cells of the first battery module to one or more battery cells of the second battery module. By redistributing the level of charge within one or more battery cells, the balancing circuit can cause the overall charge of a power supply to last longer by taking advantage of excess charge found within one or more battery cells. Additionally, the balancing circuit may be connected to a bus bar that may be utilized to power additional accessories within a vehicle.

Abstract: Various embodiments of a mining vehicle are disclosed. The embodiments provide mining vehicles that are battery powered rather than diesel powered. The embodiments also provide vehicles that have relatively high hauling capacity relative to their length and footprint (area). The embodiments also provide vehicles with improved forward and rearward ground visibility. In addition, the mining vehicles have a higher density compared to traditional vehicles, which helps to improve traction, as well as better vehicle handing and power density because of increased power relative to diesel powered vehicles.

Abstract: A module maintenance system includes a battery module comprising at least a first battery cell and a second battery cell, and a charging device comprising a bulk output and an equalization output. The battery module has a series configuration and a parallel configuration. In the parallel configuration, the charging device outputs a first voltage to the equalization output to equalize charge levels of the first and second battery cells. In the series configuration, the charging device outputs a second voltage to the bulk output to modify charge levels of the first and second battery cells, wherein the second voltage is greater than the first voltage.

Abstract: A method and system for swapping batteries in an electric vehicle is disclosed. The method includes dismounting a first battery assembly, moving to a second battery assembly and mounting the second battery assembly onto the vehicle. Mounting and dismounting are accomplished by an onboard mounting and dismounting system. The method can be used in a zero infrastructure environment such as an underground mine since mounting and dismounting are accomplished by components on the vehicle itself. An auxiliary battery pack powers the vehicle during between dismounting a battery pack and mounting another battery pack.

Abstract: A mounting and dismounting system for a battery assembly is disclosed. The system may be located onboard of an electric vehicle powered by a battery pack disposed in the battery assembly. The system includes a pair of four-bar linkages that can be used to raise and lower the battery assembly. Each four-bar linkage includes a pair of hooks with different vertical positions. The hooks are positioned to grasp horizontal mounting bars that are disposed on the battery assembly. Using vertically displaced hooks ensures the battery can be raised and lowered without rocking.

Abstract: A battery module having a plurality of battery cells is described. The battery module includes a head unit with corresponding conical positive and negative terminals that allow additional battery modules to mate together and be electrically coupled in an end-to-end relationship. A plurality of battery modules can be combined together into rows of modules that are the electrically coupled to form a multi-modular battery system. The multi-modular battery system uses interchangeable individual battery modules for ease of replacement. Battery modules of a multi-modular battery system can communicate with each other using optical communication methods, including via line-of-sight and/or optical cables.

Abstract: A zero emissions electrically powered haul truck is disclosed. The haul truck has a 40 metric ton hauling capacity and a form factor that allows the truck to travel through underground mines. The truck also includes a primary battery assembly that is externally mounted along the front and sides of the truck.

Abstract: A flexible connector a battery system and a method for assembling in a battery assembly. The apparatus can include a plurality of pads that are secured to a central spine. The flexible connector may be a single piece connector. The flexible connector can include monitors that are mounted to the flexible connector to gather data regarding battery cells.

Abstract: A method and system for swapping batteries in an electric vehicle is disclosed. The method includes dismounting a first battery assembly, moving to a second battery assembly and mounting the second battery assembly onto the vehicle. Mounting and dismounting are accomplished by an onboard mounting and dismounting system. The method can be used in a zero infrastructure environment such as an underground mine since mounting and dismounting are accomplished by components on the vehicle itself. An auxiliary battery pack powers the vehicle during between dismounting a battery pack and mounting another battery pack.

Abstract: The disclosed battery management system generally includes at least one bi-directional balancing circuit and a power supply including a first battery module and a second battery module, each having at least one battery cell. The balancing circuit may be configured to transfer excess charge from one or more battery cells of the first battery module to one or more battery cells of the second battery module. By redistributing the level of charge within one or more battery cells, the balancing circuit can cause the overall charge of a power supply to last longer by taking advantage of excess charge found within one or more battery cells. Additionally, the balancing circuit may be connected to a bus bar that may be utilized to power additional accessories within a vehicle.

Abstract: An apparatus and battery system are disclosed. The apparatus includes a first panel, a first bus bar, and a second panel. The first panel includes a first upper surface and a first lower surface. The first upper surface includes a first cavity extending into the first upper surface towards the first lower surface. The first bus bar is within the first cavity. The second panel has a second lower surface in direct contact with the first upper surface. The second lower surface extends over a substantial portion of the first cavity.

Abstract: A battery module having a plurality of battery cells is described. The battery module includes a head unit with corresponding conical positive and negative terminals that allow additional battery modules to mate together and be electrically coupled in an end-to-end relationship. A plurality of battery modules can be combined together into rows of modules that are the electrically coupled to form a multi-modular battery system. The multi-modular battery system uses interchangeable individual battery modules for ease of replacement. Battery modules of a multi-modular battery system can communicate with each other using optical communication methods, including via line-of-sight and/or optical cables.

Abstract: A module maintenance system includes a battery module, a charging device, and a rig. The battery module has a series configuration and a parallel configuration. In the parallel configuration, the rig connects each battery cell of the battery module in parallel and the charging device charges each battery cell of the battery module using the rig. In the series configuration, the battery module serially connects each battery cell of the battery module to a first terminal and a second terminal and the charging device charges each battery cell of the battery module using the first terminal and the second terminal.