GB2620910A

GB2620910A - Modular battery power supply system for use on construction sites

Info

Publication number: GB2620910A
Application number: GB2210145.5A
Authority: GB
Inventors: Williams Thomas
Original assignee: Wearable Link Ltd
Current assignee: Wearable Link Ltd
Priority date: 2022-07-11
Filing date: 2022-07-11
Publication date: 2024-01-31
Also published as: GB202210145D0

Abstract

A modular battery power supply system is disclosed, suitable for use on construction sites. The battery power supply system includes a first housing 10, which advantageously may be mounted on a road vehicle or on a trailer towable by a road vehicle 100. The first housing may be towed to an electric vehicle charging station for recharging. The first housing has receiving positions 14 for a plurality of battery modules 16. Battery modules 16 can be individually removed from the first housing 10 and used with a power adaptor (figure 2, 26) for use on individual jobs around a construction site.

Description

MODULAR BATTERY POWER SUPPLY SYSTEM FOR USE ON CONSTRUCTION SITES

The present invention relates to a modular battery system, particularly to a modular battery system suitable for providing power on a construction site.

BACKGROUND TO THE INVENTION

On construction sites of all sizes, electrical power is required for various purposes. A site office will require power for office equipment and lighting. Welfare units need power for lighting, hot water, and small kitchen equipment, e.g. kettles, microwaves. Although battery powered tools are improving all the time, heavier duty tools are still typically powered by a 110v supply (and battery powered tools still need charging). Flood lighting may be required to extend the working day beyond daylight hours in the winter months, and so on.

Currently, to provide power on construction sites diesel generators are commonly used. Various sizes of generators are available and various different sizes are often found in use around a typical site. For example, a larger generator may be lifted by a crane or forklift off a lorry. These generators, once on site, will generally stay in one place to provide a stationary supply, for example associated with a site office and welfare unit. Smaller generators, e.g. generators which can be moved relatively easily around the site on wheels, for example by towing with a van, are also used. Smaller generators still, which may be hand portable, could be used to power a single tool.

Diesel generators create noise, fumes, emissions, and safety problems. The fuel is costly and a supply of fuel needs to be maintained -i.e. time is used to drive to a fuel station and fill up fuel containers. Any spillage creates an environmental problem. Generators produce emissions which include carbon dioxide, a greenhouse gas, and also carbon monoxide, which is toxic. Fatal accidents have been reported where small generators have been used in confined spaces without adequate ventilation.

Smaller generators often run on petrol and this leads to further hazards particularly associated with handling and storing the fuel.

A medium or large site will often have a number of subcontractors working on the site at the same time. Each subcontractor will typically need to provide their own generator(s) and fuel. This leads to inefficiencies.

On a large construction project, it may be worthwhile to provision a temporary supply from the local electricity distribution network for use while the project is underway. However, there is a relatively large cost associated with this and it will not be worthwhile for smaller projects for example those programmed for only a few months.

Even when a temporary supply from the grid is provisioned, it will probably not be available to power tools in all areas of a large site -so while the welfare unit and site office may be connected to the electricity distribution network, diesel generators are still likely to be used to power tools and other loads around the site.

It is an object of the present invention to reduce or substantially obviate the aforementioned problems. In particular it is an object of the invention to provide a battery-based power supply for use on construction sites, which avoids the need to use diesel generators.

STATEMENT OF INVENTION

According to the present invention there is provided a modular battery power supply system for use on a construction site, the system comprising: a plurality of battery modules, each battery module including a plurality of cells in a module housing, and having terminals on the module housing for connection to a charger or a load; and a first housing adapted to receive multiple battery modules of the plurality of battery modules, the first housing being configured to receive and releasably retain each battery module in a position in which the terminals of the battery module are electrically connected to corresponding battery connection terminals in the first housing, the first housing including a power input port for receiving power from an electrical supply to charge the multiple battery modules retained in the first housing, a power converter, and an output port for connection to a load, the power convertor being electrically connected to the battery connection terminals for drawing power from the multiple battery modules retained in the first housing, and being electrically connected to the output port for supplying power to a load connected to the output port.

Advantageously, the system provides a flexible power supply for use on a construction site. The first housing may be provided on a trailer chassis, or even built into a vehicle, including a road vehicle. It is envisaged that the first housing would take the place of the large generators typically lifted or towed onto a building site. The first housing may be located, for example, adjacent a site office or welfare unit, and the site office and/or the welfare unit may be connected to the output port of the first housing. The first housing, loaded with multiple battery modules, provides a large amount of stored energy and can be treated for most purposes the same way as a grid-connected mains supply. The power converter on the first housing is typically an inverter providing an ordinary domestic 240v single phase supply, and may be rated for example to supply at least 3kW, preferably at least 5kW or even larger loads, for example where kitchens or electric heating need to be provided in temporary buildings.

It will be understood that multiple outputs may well be provided in a typical embodiment, potentially associated with multiple different power converters. For example in addition to the 240v domestic supply, a 110v centre-tapped supply may be provided for powering construction tools. DC outputs could be provided for charging portable tool batteries.

Providing the first housing on a trailer chassis or road vehicle means that it can be towed or driven to an electric vehicle recharging station for recharging. It is envisaged that on a typical site, this may need to be done once every few days. Typically, a construction company or power provider would have one first housing charging at a depot or charging station, and simply swap a trailer full of fully recharged battery modules for a trailer full of depleted modules, leading to minimal downtime. The labour involved in swapping over a trailer for recharging is minimal, and much safer, compared with the current process of filling fuel cans with diesel, storing the cans and distributing them around the site.

A high-power electric vehicle charger allows for fast charging of all the battery modules docked into the first housing. Public "rapid" electric car chargers are rated at 40kW or even more and can deliver a large amount of energy in a short space of time. However, even charging from a domestic 13A supply may be useful for example when one trailer can be left charging at a builder's yard while another one is in use on a construction site When a power supply is needed remotely from where the first housing is positioned, one of the battery modules can be simply removed from the first housing and carried to where it is required. Typically, the modules are hand portable, for example with a mass of less than 20kg, preferably less than 15kg or even lighter. A carrying handle may be provided to make transporting the battery module around the site easy.

A power adaptor configured to be releasably retainable to any one of the plurality of battery modules may be provided.

The power adaptor may include input terminals positioned to be in electrical contact with the terminals of the battery module, when the battery module is retained on the power adaptor. The power adaptor may include a power convertor. The power adaptor may include an output terminal for connection to a load.

The power adaptor may be clipped on to the battery module and used to power a tool. Typically, the power adaptor will include an inverter with a 11N centre-tapped output for UK tools complying with BS7375, though it will be understood that different embodiments can be provided to suit different local requirements. This is advantageous as it allows a battery module to be used as an induvial power source. That is to say, an individual battery module may be removable from the first and/or second housing for supplying power.

The battery modules may be loaded into receiving positions or "docks" in the first housing, and may be releasably retainable for example by a spring-loaded mechanism.

In some embodiments, a second housing is provided. The second housing is envisaged to be smaller than the first housing, but larger than a single battery module. For example, the second housing may be adapted to receive for example between 2 and six battery modules. The second housing may be mounted on wheels and may be movable by hand (of similar size and weight to a loaded wheelbarrow) or could be slightly larger and moved around a site for example by forklift. The second housing could be used where power is required for a period of time in a particular part of the site, for example for a few days, and where the power requirement is more than a single tool. The second housing could also be used in stationary / long-term, but low power application, for example to power lighting.

Housings of different sizes may be provided, all accepting the same battery modules which are recharged in the first housing, by towing or driving to an electric car charging station. Each housing receives a number of battery modules and provides power output for tools, domestic supplies, lighting, and any other application where electrical power is required on a construction site.

As well as construction sites, the system may be useful in other contexts such as at outdoor festivals and events, seasonal campsites, and indeed anywhere that power is required where a connection to the grid is not possible or not economical.

Preferably, locking means are provided for preventing removal of a battery module from the first housing when the locking means are engaged. In its simplest form, each battery module is mechanically locked to the first housing and can be released for example by use of a key, preventing or limiting the possibility of theft. However, more usefully, the locking means may be controlled electronically, for example by codes, passwords or electronic fobs / tags. An identity module may identify a particular authorised user by a password, electronic tag, or any other means. This not only provides security but also allows usage of battery modules to be tracked according to who is using them. The locking means may be electronically released in response to identification of an authorised user.

This allows use of battery modules around the site to be monitored. If battery modules go missing, they should be easier to find because the user who has "signed it out" will be identifiable. It also allows for power consumption to be centrally managed and charged to individual users, e.g. subcontractors on the site. This encourages more economical use of power and also allows replenishment of the supply (typically by driving the first housing to an electric car charging station) to be planned so that it happens soon enough that power does not run out, but not so often that labour is wasted.

Individual outputs on the first housing and/or outputs on second or further housings, may also be activated in response to an authorised user being identified. Usage of power, whether by "plugging in" to the first housing or by using a battery module separately, can then be recorded and, if required, billed for.

In some embodiments, energy usage monitors may be provided. The energy usage monitors are provided at the point where power is used and in different embodiments may be provided as part of, or attached to, each battery module, each power adaptor, each output of the first housing, second housing, and any further housings, or even on loads such as tools, lights, etc. Providing an energy usage monitor associated with each battery module is in principle the simplest way to record energy use, especially where battery modules are only released from the first housing on identification of an authorised user, since the battery module can then associated with that particular user until replaced in the first housing. However, other possibilities can lead to other advantages. For example, providing energy usage monitors associated with individual loads can provide information not only as to who is using power and how much, but how the power is being used.

Opportunities for savings can then be identified -for example if large amounts of power are being used for lighting, then the amount, positioning, and on-time of lighting on the site could be reviewed with a view to identifying savings.

In some embodiments, energy monitors may communicate with personal identification tags associated with individuals working on the site. In this way, the battery module does not necessarily need to be returned to the first housing and "signed in" and "signed out" again to record a change of user. For example the personal identification tag may be the wearable device described in GB2560392.

The energy usage monitors may communicate wirelessly with the hub via other devices. This may avoid the need for large antennas on each energy usage monitor for example, since the communication needs to be only very short range, for example up to about five metres. Other devices, for example the wearable device of GB2560392, may then pass the information to the central hub. In principle a "store and forward" system may be used so that it does not matter if a particular node in the system is currently out of range -it will eventually return to an in-range location and pass on stored information.

In some embodiments, a wired (or at least, physical contact) instead of wireless connection could be used, bearing in mind that all battery modules will at some point be returned to the first housing, at which point stored usage information could be "downloaded" from them.

The energy usage monitors record when power is used. Preferably, the energy usage monitors include wireless communication means, for transmission of usage information to a central hub. The central hub may be provided as part of the first housing, or may be separate. Usage information may then be used for planning, reporting and/or billing / accounting purposes.

Preferably, positioning means are provided associated with the energy usage monitors. In this way, the location at which energy is used can be recorded and reported. This can provide very useful reporting which can be used to identify areas of high energy usage, and potential opportunities for savings.

The positioning means may be, for example, satellite positioning system receivers.

However, it is preferred in some embodiments to use positioning means relying on terrestrial base stations. This may provide more reliable positioning especially on partially indoor / partially outdoor sites where satellite positioning systems may not work effectively. Sites in tunnels, for example, where satellite positioning will not work at all, will also rely on base stations on the site itself.

In some embodiments, at least rough energy usage location information could be derived from battery modules which record their position, but which do not have associated energy monitors for recording power use directly. If the state of charge of the battery module can be measured when the battery module is removed from the first housing and then measured again when the battery module is replaced in the first housing, then the amount of energy used while the battery module was "out" can be calculated. This could be averaged over the locations in which the battery module has been positioned while it was "out". In many typical scenarios, the battery module would be removed from the first housing, used for a job at a particular location on the site, and then returned. In such a scenario the information derived from a positioning means on the battery module, but where only the overall depletion of the battery during its use time is known, would be a fairly good estimate of the amount of power used at a particular location.

Advantageously, energy usage patterns can be overlaid on a map of the site and presented as a "heat map", showing a site manager where on the site energy is being used.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which: Figure 1 shows the first housing, part of the system of the invention; Figure 2 shows an individual battery module, one of the plurality of battery modules in the system of the invention, together with a power adaptor; Figure 3 shows second housing for use with two of the battery modules of Figure 2; and Figure 4 shows an example of a user interface in a power management system, showing energy use overlaid on a map of a construction site.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring firstly to Figure 1, a first housing forming part of the system of the invention is shown generally at 10. In this embodiment, the first housing is mounted on a trailer, having wheels 12 and a trailer hitch 13. The trailer can be towed by a vehicle 100, so that it can be conveniently transported by road. In particular, the trailer can be towed to an electric car charging station such as those which are commonly provided for public use at service stations.

The first housing 10 comprises a plurality of receiving positions or docks 14 for battery modules. A battery module 16 can be received into each receiving position 14, and when received into position terminals on the battery module 16 will make electrical contact with corresponding terminals on the housing 10. Circuitry / connections within the first housing allows the battery modules to be charged by a single input port 18, and supply power to loads connected to an output port 20.

The first housing 10 mechanically retains the battery modules 16 in position to prevent them from falling out (even when subject to vibration such as when being towed on the road), prevent theft, and also to ensure that usage of the battery modules 16 can be monitored and controlled. Locking means for retaining the batteries in place may be electronically actuated, for example with a solenoid lock to prevent removal of a battery module except when the locking means is released.

In this example embodiment, a keypad 22 is provided for controlling the locking means.

A personal identification number may be entered into the keypad 22 to release the locking means and remove a battery module. Not only does this limit use to authorised users, but individual users can be issued with individual identification numbers, and hence usage of battery modules can be recorded and used for example for accounting / billing purposes.

In other embodiments, alternatively or in addition to the keypad, personal identification tags, RFID fobs, or similar, may be used to identify authorised users and release the locking means. In particular, the wearable device described in GB2560392 may be used as a suitable identification tag.

Figure 2 shows a single battery module 16. The battery module in this embodiment is made from an "Essential" assembly from Aceleron Energy. This is a fully serviceable battery in which individual cells may be replaced, minimising waste when cells fail.

A battery coupling 24 is provided. This allows the battery module 16 to be clipped into another device, and be electrically connected to the second device. While clipped in, that device and battery will not accidentally come apart, but can be easily removed from each other for example by operating a sprung catch. The kind of coupling envisaged is similar to that used on many cordless power tools, for example drills and screwdrivers, but somewhat larger.

\Mien the battery module 16 is received into a receiving position 14 of the first housing, it is clipped into the first housing and electrically connected to the first housing using the coupling 24. The same coupling 24 is used to connect the battery module to a power adapter 26, when the battery module is to be used on its own, for example to power a tool on a part of the construction site remote from where the first housing 10 has been deployed. The power adaptor in this embodiment includes an inverter for providing a 11N centre-tapped output (i.e. three wires at -55v, Ov and +55v). However, power adaptors providing other kinds of power outputs (for example 240v single phase for ordinary domestic equipment, or DC supplies for charging small battery powered items) could also be provided.

Figure 3 shows a second housing 28. The second housing 28 is smaller than the first housing 10 but larger than an individual battery module 16. For example, in this embodiment the second housing 28 can be loaded with two battery modules 16. The second housing includes a power converter, for example to provide a 11N centre-tapped or 240v single phase AC supply. Hence the second housing 28 may be suitable for higher load applications, or longer term use for example for lighting, than a single battery module 16. However, the second housing 28 is still portable by hand, by pushing or pulling it on the wheels 30. The second housing 28 may have similar size and weight, and similar manoeuvrability, to a loaded wheelbarrow.

As explained, battery modules 16, or indeed other components of the system, may be provided with energy usage monitors and positioning means. In this way, energy usage can be recorded and linked to a user and also a location on site. Figure 4 shows an example user interface in which a plan of a construction site is overlaid with a "heat map" showing energy use in different locations. This information is useful to a site manager who may use it to review energy usage and identify possible inefficiencies and therefore potential savings. Also, a high power requirement in a particular location may lead to a decision to move the first housing or deploy an additional first housing, to minimise the amount of carrying around of battery modules which is required.

The system of the invention provides an excellent alternative to the diesel and petrol generators which are currently ubiquitous on construction sites. Electrical power for site offices, welfare units, lighting, and tool use on individual jobs is provided by the battery modules which can be used either as part of the first housing, the second housing, or on their own with a connected power adaptor. Energy usage is recorded and linked to both user and location, to allow efficiencies to be identified and to allow a site manager to ensure that power is always available when required and time is not lost. The first housing, being mounted on a trailer or vehicle, can easily be charged by towing it to an electric car charging station. Diesel or petrol does not need to be bought, transported, or stored. There is no health and safety risk from fumes and there are no greenhouse gas emissions at the point of use. Renewable and zero-carbon electricity may be bought from the grid (or even obtained locally from, for example, solar panels at a builder's depot). Compatibility with public electric car chargers means that obtaining electricity will not be a problem even when the site is some distance from a depot.

The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.

Claims

CLAIMS1. A modular battery power supply system for use on a construction site, the system comprising a plurality of battery modules, each battery module including a plurality of cells in a module housing, and having terminals on the module housing for connection to a charger or a load; a first housing adapted to receive multiple battery modules of the plurality of battery modules, the first housing being configured to receive and releasably retain each battery module in a position in which the terminals of the battery module are electrically connected to corresponding battery connection terminals in the first housing, the first housing including a power input port for receiving power from an electrical supply to charge the multiple battery modules retained in the first housing, a power converter, and an output port for connection to a load, the power convertor being electrically connected to the battery connection terminals for drawing power from the multiple battery modules retained in the first housing, and being electrically connected to the output port for supplying power to a load connected to the output port; and a power adaptor configured to be releasably retainable to any one of the plurality of battery modules, the power adaptor including input terminals positioned to be in electrical contact with the terminals of the battery module, when the battery module is retained on the power adaptor, the power adaptor further including a power convertor, and an output terminal for connection to a load.
2. A modular battery power supply system as claimed in claim 1, in which the first housing is mounted to a road vehicle.
3. A modular battery power supply system as claimed in claim 1, in which the first housing is mounted to a trailer towable by a road vehicle.
4. A modular battery power supply system as claimed in any of the preceding claims, in which the power converter associated with the first housing includes an inverter having an AC output.
5. A modular battery power supply system as claimed in claim 1, in which the power input port of the first housing is suitable for connection to an electric vehicle charger.
6. A modular battery power supply system as claimed in claim 5, in which the power input port of the first housing is suitable for receiving at least 40kW of power.
7. A modular battery power supply system as claimed in any of the preceding claims, in which each of the battery modules is hand portable.
8. A modular battery power supply system as claimed in claim 7, in which each of the battery modules has a mass of less than 20kg.
9. A modular battery power supply system as claimed in claim 7 or claim 8, in which each of the battery modules is provided with a carrying handle.
10. A modular battery power supply system as claimed in any of the preceding claims, in which a second housing is provided, the second housing being adapted to receive a smaller number of battery modules than the first housing.
11. A modular battery power supply system as claimed in claim 10, in which the second housing is provided with wheels and is movable by hand.
12. A modular battery power supply system as claimed in any of the preceding claims, in which locking means are provided for preventing removal of a battery module from the first housing when the locking means are engaged.
13. A modular battery power supply system as claimed in claim 12, in which an identity module is provided for identifying authorised users, the locking means being disengaged on an authorised user being identified
14. A modular battery power supply system as claimed in claim 13, including storage means for storing a log of identified authorised users associated with battery modules removed from the first housing.
15. A modular battery power supply system as claimed in any of the preceding claims, in which energy usage monitors are provided for recording use of power drawn from the system.
16. A modular battery power supply system as claimed in claim 15, in which an energy usage monitor is associated with each battery module.
17. A modular battery power supply system as claimed in claim 15 or claim 16, in which the energy usage monitors communicate wirelessly with a central hub.
18. A modular battery power supply system as claimed in claim 17, in which the central hub is provided as part of the first housing.
19. A modular battery power supply system as claimed in any of the preceding claims, in which positioning means are provided.
20. A modular battery power supply system as claimed in claim 19, in which a positioning means is associated with each battery module.
21.A modular battery power supply system as claimed in claim 19 or claim 20, when dependent on any of claims 15 to 18, in which the energy usage monitors are configured to record energy use against the location at which the energy was used.