Battery replacement method

Abstract

This invention discloses a battery swapping method, comprising: removing a depleted battery pack from an electric vehicle and placing it in a first position; flipping the removed depleted battery pack from the first position along a first direction to a second position; placing the depleted battery pack in the second position into a charging compartment for charging, and / or removing a fully charged battery pack from the charging compartment and placing it in a third position; flipping the removed fully charged battery pack from the third position along a second direction to a fourth position; and placing the fully charged battery pack in the fourth position into the electric vehicle. This battery swapping method enables the retrieval and placement of large battery packs within a charging station with a smaller space and structure. This simplifies the battery swapping process and increases the swapping speed. Furthermore, it allows for battery replacement of electric vehicles using a single large battery pack within a smaller battery swapping station footprint, thereby reducing battery pack costs and facilitating widespread adoption.

Description

[0001] This application is a divisional application of Chinese patent application filed on April 3, 2020, with application number 202010262662.1 and entitled "Battery Swapping Method". Technical Field

[0002] This invention relates to a battery swapping method. Background Technology

[0003] Currently, the electric vehicle battery swapping field mainly divides into two types: chassis battery swapping and side battery swapping. Side battery swapping involves extracting the battery pack from the vehicle using a swapping device, rotating it 180° on the device's surface so that the charging port faces the charging compartment instead of the vehicle, and then inserting the battery into the charging compartment on the other side of the swapping device for charging. Due to the structural constraints of the vehicle itself, most current methods use side battery swapping. Side battery swapping requires the swapping device to rotate the battery pack 180° on the device before inserting it into the charging compartment for charging.

[0004] However, since the battery pack needs to be rotated in a plane, the long and narrow battery pack requires a lot of space to rotate, which leads to the complex structure and large size of the battery swapping equipment. This not only directly affects the manufacturing difficulty of the battery swapping equipment, but also increases the footprint of the battery swapping station. Therefore, electric vehicles can only use the form of swapping multiple small battery packs. However, the battery swapping method of multiple battery packs requires swapping on both sides, which makes the battery swapping process cumbersome and the swapping time longer. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the existing battery swapping methods, which require complex battery swapping equipment structures, resulting in high manufacturing difficulty, large area occupied by battery swapping stations, and cumbersome and time-consuming battery swapping processes, and to provide a battery swapping method.

[0006] The present invention solves the above-mentioned technical problems through the following technical solution:

[0007] A battery swapping method, characterized in that the battery swapping method includes:

[0008] Remove the depleted battery pack from the electric vehicle and place it in the first position;

[0009] The removed, depleted battery pack is flipped from the first position to the second position along the first direction;

[0010] Place the depleted battery pack in the second position into the charging compartment for charging, and / or remove the fully charged battery pack from the charging compartment and place it in the third position.

[0011] Flip the fully charged battery pack from the third position to the fourth position along the second direction;

[0012] The fully charged battery pack, located in the fourth position, is placed into the electric vehicle.

[0013] In this mechanism, the first and fourth positions can be the same, and the second and third positions can be the same. Therefore, the flipping mechanism mainly flips between two positions.

[0014] This invention employs a flipping method to rotate the battery pack. The flipping of the battery pack itself requires less space, and the flipping mechanism is structurally significantly smaller compared to planar rotating battery swapping devices. Therefore, the battery swapping method of this invention can complete the retrieval and placement of large battery packs within a charging station with a smaller space and structure. This simplifies the battery swapping process and increases the swapping speed. Furthermore, it allows for battery replacement of electric vehicles using a single large battery pack with a smaller battery swapping station footprint, thereby reducing battery pack costs and facilitating widespread adoption.

[0015] Preferably, the battery swapping method utilizes a flipping mechanism to flip a depleted or fully charged battery pack, wherein...

[0016] Removing a depleted battery pack from an electric vehicle and placing it in a first position includes: removing a depleted battery from an electric vehicle and placing it in a first position on the flipping mechanism;

[0017] Alternatively, removing a fully charged battery pack from the charging compartment and placing it in the third position includes: removing a fully charged battery pack from the charging compartment and placing it in the third position of the flipping mechanism.

[0018] The flipping mechanism in this invention rotates the battery pack by flipping. The flipping of the battery pack itself requires less space, and the structure of the flipping mechanism is significantly smaller compared to planar rotating battery swapping devices. Therefore, the battery swapping device of this invention can complete the loading and unloading of larger battery packs in charging stations with a smaller space and structure. Thus, battery swapping of electric vehicles using a single large battery pack can be achieved with a smaller battery swapping station footprint, thereby reducing battery pack costs and facilitating widespread adoption.

[0019] Preferably, a battery loading and unloading mechanism is provided to enable the loading and unloading of the battery pack from the electric vehicle or charging compartment; wherein,

[0020] Removing a depleted battery pack from an electric vehicle and placing it in a first position includes: controlling the battery removal and placement mechanism to remove the depleted battery pack from the electric vehicle and place it in a first position on the flipping mechanism;

[0021] Alternatively, removing a fully charged battery pack from the charging compartment and placing it in the third position includes: controlling the battery loading and unloading mechanism to remove a fully charged battery pack from the charging compartment and place it in the third position of the flipping mechanism.

[0022] Preferably, an extension mechanism is provided on the flipping mechanism for taking out and placing the battery pack located on the electric vehicle and the charging compartment;

[0023] Removing a depleted battery pack from an electric vehicle and placing it in a first position includes: controlling an extension mechanism to extend toward the electric vehicle; controlling the extension mechanism to lift the depleted battery pack located inside the electric vehicle; and controlling the extension mechanism to retract so that the depleted battery pack reaches a first position on a flipping mechanism.

[0024] Alternatively, removing a fully charged battery pack from the charging compartment and placing it in the third position includes: controlling the extension mechanism to extend towards the charging compartment; controlling the extension mechanism to lift the fully charged battery pack located in the charging compartment; and controlling the extension mechanism to retract so that the fully charged battery pack reaches the third position on the flipping mechanism.

[0025] The extension mechanism can transfer the battery pack by moving itself, thus enabling the battery pack to move on the first and second flipping parts.

[0026] Before the extension mechanism extends towards the electric vehicle, it also includes a step of aligning with the battery pack on the electric vehicle / charging compartment. This is achieved through detection devices such as sensors or a guideable mechanical structure, enabling the extension mechanism to be spatially aligned with the battery pack before moving and extending towards it.

[0027] The battery loading / unloading mechanism and the flipping mechanism can be the same or different mechanisms. The battery loading / unloading mechanism can be an external, independent mechanism, such as a telescopic mechanism inside the electric vehicle or a transfer mechanism inside the charging compartment. In this case, the flipping mechanism only needs to be aligned to transfer the battery pack. The battery loading / unloading mechanism can also be a separate, mobile transport mechanism responsible for moving the battery pack between the flipping mechanism and the charging compartment or charging vehicle.

[0028] Preferably, controlling the removed depleted battery pack to flip from the first position to the second position along the first direction includes:

[0029] Determine whether the battery pack is located in the first position;

[0030] If so, the flipping mechanism is controlled to flip the depleted battery pack along the first direction;

[0031] Determine whether the battery pack has reached the second position;

[0032] If so, the flipping mechanism is controlled to stop flipping the depleted battery pack.

[0033] Preferably, the flipping mechanism includes a first flipping part and a second flipping part. The first flipping part is used to carry a battery pack located at a first position or a fourth position, and the second flipping part is used to carry a battery pack located at a second position or a third position. The first flipping part and the second flipping part are arranged perpendicular to each other.

[0034] The first and second flipping sections respectively support the battery pack at different locations, corresponding to the placement and removal of the battery pack on the electric vehicle side and the charging compartment side. Specifically, the first flipping section docks with the electric vehicle to facilitate the placement and removal of the battery pack, while the second flipping section docks with the charging compartment to facilitate the placement and removal of the battery pack.

[0035] Preferably, the flipping mechanism includes a first flipping part and a second flipping part, wherein the first flipping part is used to carry a battery pack located at a first position or a fourth position, and the second flipping part is used to carry a battery pack located at a second position or a third position, wherein the battery swapping method further includes:

[0036] The system checks whether the first and second flipping parts have rotated to the correct positions. If they have rotated to the correct positions, the system starts moving the battery pack. If they have not rotated to the correct positions, the system continues to rotate.

[0037] And / or detect whether the battery pack has moved into place on the first or second flipping part. If it has moved into place, start rotating the first or second flipping part. If it has not moved into place, continue moving.

[0038] Preferably, the charging compartment is provided with a floating disk for carrying the battery and an electrical connector for forming an electrical connection with the battery pack to charge and discharge the battery pack. Placing the depleted battery pack located in the second position into the charging compartment for charging includes:

[0039] Move the depleted battery pack into the floating disk inside the charging compartment;

[0040] The control connector moves toward the depleted battery pack and forms an electrical connection.

[0041] This solution utilizes the gravity of the battery pack to move the floating disk. By setting a linkage mechanism between the floating disk and the electrical connector, the electrical connector is driven to move towards the battery pack to form an electrical connection. In other words, the electrical connection is achieved using the gravity of the battery pack itself, without the need for additional power to drive the electrical connector to move. Moreover, this linkage method is applicable to electrical connections in various orientations of the battery pack.

[0042] Preferably, a linkage mechanism is provided between the floating disk and the electrical connector. The floating disk can float up and down under the gravity of the battery pack. The linkage mechanism is used to drive the electrical connector to move closer to or away from the battery when the floating disk floats up and down. Placing the depleted battery pack located in the second position into the charging compartment for charging includes:

[0043] Place the depleted battery pack on the floating plate inside the charging compartment and align the electrical connectors and terminals of the battery pack.

[0044] The floating disk floats downwards by a first displacement under the influence of the battery's gravity.

[0045] The linkage mechanism drives the electrical connector to move a second displacement toward the battery pack and forms an electrical connection with the battery pack.

[0046] The first floating direction is vertically downward, meaning that the weight of the battery pack can be fully utilized by the floating disk, allowing the floating disk to drive the movement of the linkage mechanism more promptly.

[0047] Preferably, the floating disk is equipped with a reset element, and removing the fully charged battery pack from the charging compartment and placing it in the third position includes:

[0048] The fully charged battery pack is removed from the floating disk inside the charging compartment and placed in the third position of the flipping mechanism;

[0049] The floating disk floats upward by a first displacement under the action of the reset element;

[0050] The linkage mechanism drives the electrical connector to move a second displacement away from the battery pack and detach it from the battery pack.

[0051] Preferably, the second displacement is greater than the first displacement.

[0052] Preferably, the linkage mechanism includes a sliding mechanism, a first traction member, and a second traction member. The first traction member is connected to the sliding mechanism and the floating disk, respectively. The second traction member is connected to the electrical connector and a mounting base, respectively. The electrical connector is mounted on the mounting base and moves relative to the mounting base. The second traction member is slidably connected to the sliding mechanism.

[0053] This constitutes the structure of the movable pulley. The second traction member moves twice the distance of the first traction member, thus achieving a second displacement greater than the first displacement.

[0054] Preferably, placing the depleted battery pack in the second position into the charging compartment for charging includes:

[0055] Move the depleted battery pack into the floating disk inside the charging compartment;

[0056] The first traction member is driven by the floating disk and pulls the sliding mechanism;

[0057] The second traction member is driven by the sliding mechanism and pulls the electrical connector;

[0058] The electrical connector moves toward the depleted battery pack and forms an electrical connection.

[0059] Preferably, removing the fully charged battery pack from the charging case includes:

[0060] Remove the fully charged battery pack from the floating disk inside the charging compartment;

[0061] The floating disk floats upward by a first displacement under the action of the reset element;

[0062] The first and second traction components move in accordance with the floating disk and the electrical connector;

[0063] The electrical connector moves a second displacement away from the battery pack and disengages from the battery pack.

[0064] Preferably, the battery pack is moved toward the charging compartment or electric vehicle while rotating the battery pack; or the battery pack is moved toward the charging compartment or electric vehicle after rotating the battery pack; or the battery pack is moved toward the charging compartment or electric vehicle before rotating the battery pack.

[0065] The significant advantages of this invention are: the battery pack itself requires less space to flip, and the flipping mechanism is structurally significantly smaller compared to planar rotating battery swapping devices. Therefore, the battery swapping method of this invention can complete the loading and unloading of larger battery packs in charging stations with a smaller space and structure. This simplifies the battery swapping process and increases swapping speed. Furthermore, it enables battery replacement for electric vehicles using a single large battery pack within a smaller battery swapping station footprint, thereby reducing battery pack costs and facilitating widespread adoption. Attached Figure Description

[0066] Figure 1 This is a flowchart of the battery swapping method according to Embodiment 1 of the present invention.

[0067] Figure 2 This is an overall structural diagram of the battery swapping equipment according to Embodiment 1 of the present invention.

[0068] Figure 3 This is a structural diagram of the battery swapping equipment of Embodiment 1 of the present invention after being rotated 90 degrees.

[0069] Figure 4 This is a bottom structural diagram of the battery swapping device according to Embodiment 1 of the present invention.

[0070] Figure 5 This is a structural diagram of the charging device within the charging assembly of Embodiment 1 of the present invention.

[0071] Figure 6 This is a schematic diagram of the charging assembly of Embodiment 1 of the present invention.

[0072] Figure 7 This is a schematic diagram of the arrangement of the charging devices according to Embodiment 1 of the present invention.

[0073] Figure 8 This is a structural diagram of the charging station according to Embodiment 1 of the present invention. Detailed Implementation

[0074] The present invention will be further illustrated by way of embodiments below, but the present invention is not limited to the scope of the embodiments described herein.

[0075] like Figure 1 As shown, this embodiment discloses a battery swapping method, which includes:

[0076] Step S1: Remove the depleted battery pack 4 from the electric vehicle 3 and place it in the first position;

[0077] Step S2: Flip the removed depleted battery pack 4 from the first position to the second position along the first direction;

[0078] Step S3: Place the depleted battery pack 4, located in the second position, into the charging compartment A of the charging assembly 2 for charging.

[0079] Step S4: Remove the fully charged battery pack 4 from charging compartment A and place it in the third position;

[0080] Step S5: Flip the fully charged battery pack 4 from the third position to the fourth position along the second direction;

[0081] Step S6: Place the fully charged battery pack 4, located in the fourth position, into the electric vehicle 3.

[0082] The battery swapping method in this embodiment is applicable to the replacement and transfer of battery pack 4 on electric vehicle 3 within a battery swapping station. The charging compartment A is equipped with a charging assembly 2 to charge the depleted battery pack 4 removed from electric vehicle 3 and to store fully charged battery pack 4 for continued use of electric vehicle 3. The battery swapping station is usually also equipped with battery swapping equipment, which has both battery pick-and-place and battery transfer functions. That is, the battery swapping equipment can pick up and place batteries from electric vehicle 3 and charging compartment A, and can also transfer batteries between electric vehicle 3 and charging compartment A, transferring the depleted battery pack 4 from electric vehicle 3 to charging compartment A, and transferring the fully charged battery from charging compartment A to electric vehicle 3. In other embodiments, the battery swapping equipment may only have a battery transfer function, with a separate battery pick-and-place mechanism performing the action of picking up and placing batteries from electric vehicle 3 and charging compartment A.

[0083] In this embodiment, in order to achieve the flipping of the battery pack 4, the battery swapping equipment is provided with a flipping mechanism 10. The first position is the initial position of the depleted battery pack 4 taken from the electric vehicle on the flipping mechanism 10. The first position usually corresponds to the battery pack 4 on the electric vehicle 3. The second position is the position of the depleted battery pack 4 on the flipping mechanism 10 after being flipped along the first direction. The second position corresponds to the compartment on the charging compartment A used to place the depleted battery pack 4. The third position is the initial position of the fully charged battery pack 4 taken from the charging compartment A on the flipping mechanism 10. The fourth position is the position of the fully charged battery pack 4 on the flipping mechanism 10 after being flipped along the second direction. The depleted battery pack 4 does not refer to the battery pack 4 with 0% power, but includes the situation where the remaining power of the battery pack 4 is insufficient to power the electric vehicle 3 to continue driving. The fully charged battery pack 4 does not refer to the battery pack 4 with 100% power, but includes the situation where the power of the battery pack 4 is sufficient to power the electric vehicle 3 to continue driving.

[0084] In this case, the first and fourth positions can be the same, and the second and third positions can be the same. For example... Figure 2 and Figure 3 As shown, in this embodiment, the first position and the fourth position are the same, that is, the initial position of the depleted battery pack 4 on the flipping mechanism 10 and the position of the fully charged battery pack 4 on the flipping mechanism 10 after flipping along the second direction are the same; the position of the depleted battery pack 4 on the flipping mechanism 10 after flipping along the first direction is the same as the initial position of the fully charged battery pack 4 taken out from the charging compartment A on the flipping mechanism 10. Therefore, the flipping switching of the flipping mechanism 10 mainly involves switching between two flipping states.

[0085] The flipping mechanism 10 in this solution is used to flip the battery pack 4 during the transfer of the battery pack 4 between the electric vehicle 3 and the charging compartment A, so as to accommodate the different orientations of the electrical connectors in the electric vehicle 3 and the charging compartment A.

[0086] In this invention, a flipping method is used to rotate the battery pack 4. The flipping of the battery pack 4 requires less space, and the flipping mechanism 10 is structurally significantly smaller compared to the planar rotating battery swapping device 1. Therefore, the battery swapping method of this invention can complete the retrieval and placement of a large battery pack 4 in a charging station with a smaller space and structure. This simplifies the battery swapping process and increases the swapping speed. Furthermore, it allows for battery replacement of electric vehicles 3 using a single large battery pack 4 within a smaller battery swapping station footprint, thereby reducing the cost of the battery pack 4 and facilitating its widespread adoption.

[0087] like Figures 2-8The diagram shows the structure of the battery swapping device 1 and the charging assembly 2 (including the charging device 20) that can be used to implement this battery swapping method. However, the implementation of this battery swapping method is not limited to the battery swapping device 1 and the charging assembly listed in this embodiment, and other devices can also be used.

[0088] In this embodiment, the battery swapping method uses a flipping mechanism 10 to flip the depleted or fully charged battery pack 4.

[0089] Removing the depleted battery pack 4 from the electric vehicle 3 and placing it in the first position includes: removing the depleted battery from the electric vehicle 3 and placing it in the first position on the flipping mechanism 10;

[0090] Alternatively, removing the fully charged battery pack 4 from the charging compartment A and placing it in the third position includes: removing the fully charged battery pack 4 from the charging compartment A and placing it in the third position of the flipping mechanism 10.

[0091] In this embodiment, an extension mechanism is provided on the flipping mechanism 10 for taking out and placing the battery pack 4 located on the electric vehicle 3 and the charging compartment A.

[0092] Removing the depleted battery pack 4 from the electric vehicle 3 and placing it in the first position includes: controlling the extension mechanism to extend towards the electric vehicle 3; controlling the extension mechanism to lift the depleted battery pack 4 located inside the electric vehicle 3; and controlling the extension mechanism to retract so that the depleted battery pack 4 reaches the first position on the flipping mechanism 10.

[0093] Alternatively, removing the fully charged battery pack 4 from the charging compartment A and placing it in the third position includes: controlling the extension mechanism to extend towards the charging compartment A; controlling the extension mechanism to lift the fully charged battery pack 4 located in the charging compartment A; and controlling the extension mechanism to retract so that the fully charged battery pack 4 reaches the third position on the flipping mechanism 10.

[0094] Before the extension mechanism extends towards the electric vehicle, it also includes a step of aligning with the battery pack 4 on the electric vehicle 3 / charging compartment A. This is achieved by using detection devices such as sensors or a guideable mechanical structure to align the extension mechanism spatially with the battery pack 4 before it moves and extends towards the electric vehicle 3 / charging compartment A. In other embodiments, the battery pack 4 can also be removed from the electric vehicle 3 or charging compartment A and placed in a first or third position using a separate battery loading / unloading mechanism.

[0095] In this embodiment, controlling the removed depleted battery pack 4 to flip from the first position to the second position along the first direction includes:

[0096] The battery pack 4 is determined to be in the first position by a sensor or limit switch located on the flipping mechanism 10. The sensor or limit switch can be set on the first flipping mechanism 11. After the battery pack 4 moves into position on the first flipping mechanism 11, a positioning signal is triggered.

[0097] If so, the flipping mechanism 10 is controlled to flip the depleted battery pack 4 along the first direction. In this embodiment, the rotation of the flipping motor 157 is controlled, and the rotation of the flipping mechanism 10 along the first direction is controlled by the transmission of the gear set 16. When the number of gears in the gear set is even, the flipping motor 157 rotates in the opposite direction to the first direction so that the flipping mechanism 10 rotates along the first direction; when the number of gears in the gear set is odd, the flipping motor 157 rotates along the first direction so that the flipping mechanism 10 rotates along the first direction.

[0098] The detection device, such as a sensor or limit switch located on the flipping mechanism 10, determines whether the battery pack 4 has reached the second position. The sensor or limit switch can be set on the second flipping mechanism 12. After the battery pack 4 moves into position on the second flipping mechanism 12, a positioning signal is triggered.

[0099] If so, the control flipping mechanism 10 stops flipping the depleted battery pack 4.

[0100] Controlling the fully charged battery pack 4 to flip from the third position to the fourth position along the second direction includes:

[0101] The detection device, such as a sensor or limit switch located on the flipping mechanism 10, determines whether the battery pack 4 is in the third position. The sensor or limit switch can be set on the second flipping mechanism 12. After the battery pack 4 moves into position on the second flipping mechanism 12, it triggers a positioning signal.

[0102] If so, the flipping mechanism 10 is controlled to flip the depleted battery pack 4 along the second direction. In this embodiment, the rotation of the flipping motor 157 is controlled, and the rotation of the flipping mechanism 10 along the second direction is controlled by the transmission of the gear set 16. When the number of gears in the gear set is even, the flipping motor 157 rotates in the opposite direction to the second direction so that the flipping mechanism 10 rotates along the second direction; when the number of gears in the gear set is odd, the flipping motor 157 rotates along the second direction so that the flipping mechanism 10 rotates along the second direction.

[0103] The detection device, such as a sensor or limit switch located on the flipping mechanism 10, determines whether the battery pack 4 has reached the fourth position. The sensor or limit switch can be set on the first flipping mechanism 11. After the battery pack 4 moves into position on the first flipping mechanism 11, a positioning signal is triggered.

[0104] If so, the control flipping mechanism 10 stops flipping the depleted battery pack 4.

[0105] In this embodiment, the flipping mechanism 10 includes a first flipping part 11 and a second flipping part 12. The first flipping part 11 is used to carry the battery pack 4 located at a first position or a fourth position, and the second flipping part 12 is used to carry the battery pack 4 located at a second position or a third position. The first flipping part 11 and the second flipping part 12 are arranged perpendicular to each other. The first flipping part 11 and the second flipping part 12 respectively realize the carrying of the battery pack 4 at different positions, corresponding to the loading and unloading of the battery pack 4 on the side of the electric vehicle 3 and the side of the charging compartment A, respectively. Specifically, when the first flipping part 11 is facing the first position or the fourth position, it docks with the electric vehicle 3 to realize the loading and unloading of the battery pack 4. The second flipping part 12 docks with the charging compartment A, causing the battery pack 4 to move from the second position to the charging compartment A, or from the charging compartment A to the third position, to realize the loading and unloading of the battery pack 4. In this embodiment, the first flipping part is not perfectly aligned with the electric vehicle; it may have a certain gap or deviation. Alignment with the electric vehicle is achieved through an overall moving flipping mechanism. Similarly, the first flipping part is not perfectly aligned with the charging compartment; it may have a certain gap or deviation. Alignment with the charging compartment is achieved through an overall moving flipping mechanism.

[0106] In this embodiment, it is preferable that the first flipping part 11 keeps the battery pack 4 horizontal in the first and fourth positions when docking with the electric vehicle 3. The second flipping part 12 keeps the battery pack 4 horizontal in the second and third positions when docking with the charging assembly 2.

[0107] In this embodiment, the flipping mechanism 10 includes a first flipping part 11 and a second flipping part 12. The first flipping part 11 is used to carry the battery pack 4 located at a first position or a fourth position, and the second flipping part 12 is used to carry the battery pack 4 located at a second position or a third position. The first flipping part 11 and the second flipping part 12 flip coaxially.

[0108] Detection points are provided on the rotation shafts of the first flipping part 11 and the second flipping part 12 to control the flipping angle of the first flipping part 11 and the second flipping part 12 and determine whether the battery pack 4 is in place; or detection sensors are provided on the first flipping part 11 and the second flipping part 12 to detect whether the battery pack 4 is in place.

[0109] The battery swapping method further includes: detecting whether the first flipping part 11 and the second flipping part 12 have rotated into place; if they have rotated into place, the battery pack 4 is moved; if they have not rotated into place, the rotation continues.

[0110] And / or detect whether the battery pack 4 has moved into place on the first flip part 11 or the second flip part 12. If it has moved into place, start rotating the first flip part 11 or the second flip part 12. If it has not moved into place, continue moving.

[0111] like Figures 2-4 As shown, the first flipping part 11 of this embodiment includes a first extension mechanism 111, and the second flipping part 12 includes a second extension mechanism 121. The first extension mechanism 111 and the second extension mechanism 121 can extend. The first extension mechanism 111 moves the battery pack 4 inside the electric vehicle 3 to a first position or moves the battery pack 4 from a fourth position to the electric vehicle 3. The second extension mechanism 121 moves the battery pack 4 from a second position to the charging assembly 2, or moves the battery pack 4 from the charging assembly 2 to a third position. The first extension mechanism 111 docks with the electric vehicle 3 to allow for the placement and removal of the battery pack 4. The second extension mechanism 121 docks with the charging compartment A to allow for the placement and removal of the battery pack 4.

[0112] like Figures 2-4 As shown, the first flipping part 11 in this embodiment includes a first extension mechanism 111 and a turntable 13, and the second flipping part 12 includes a second extension mechanism 121 and a turntable 13. In this embodiment, the turntable 13 is a shared part of the first flipping part 11 and the second flipping part 12. Alternatively, it can be understood that the first flipping part 11 includes the first extension mechanism 111 and the turntable 13, and the second flipping part 12 only includes the second extension mechanism 121; or it can be understood that the first flipping part 11 only includes the first extension mechanism 111, and the second flipping part 12 includes the second extension mechanism 121 and the turntable 13.

[0113] The bottom of the turntable 13 is connected to the output gear 162 via a rotating shaft 163. Therefore, when rotating, the turntable 13 rotates together. At this time, the first flipping part 11 and the second flipping part 12 achieve simultaneous flipping.

[0114] like Figures 2-4 As shown, the extension directions of the first extension mechanism 111 and the second extension mechanism 121 intersect, allowing the battery pack 4 to be relayed between the first extension mechanism 111 and the second extension mechanism 121. After the battery pack 4 is transported to the bottom on the first extension mechanism 111, it naturally contacts the second extension mechanism 121 at a first position. After flipping, it reaches a second position, where the second extension mechanism 121 carries the battery pack 4 for transport. Conversely, after the battery pack 4 is transported to the bottom on the second extension mechanism 121, it naturally contacts the first extension mechanism 111 at a third position. After flipping, it reaches a fourth position, where the first extension mechanism 111 carries the battery pack 4 for transport.

[0115] When removing the battery, the first extension mechanism 111 removes the battery pack from the electric vehicle 3, retracts, and places the battery pack 4 in the first position on the first flipping part 11. After the flipping mechanism is driven to flip 90 degrees in the first direction, the battery pack 4 is located in the second position on the second flipping part 12. The second extension mechanism 121 extends to send the battery pack 4 in the second position into the corresponding charging compartment A, and then retracts to its initial position. When replacing the battery, the battery swapping device 1 is moved to the charging compartment A containing the fully charged battery pack 4. The second extension mechanism 121 extends to remove the fully charged battery pack 4 from the charging compartment, retracts, and places the battery pack 4 in the third position on the second flipping part 12. After the flipping mechanism 10 is driven to flip 90 degrees in the second direction, the battery pack 4 is located in the fourth position on the first flipping part 11. The first extension mechanism 121 sends the battery pack 4 in the fourth position into the electric vehicle 3, and then retracts to its initial position.

[0116] In this embodiment, both the first extension mechanism 111 and the second extension mechanism 121 are telescopic forks. The telescopic fork can be any existing device capable of length-direction extension. In this embodiment, the first extension mechanism 111 and the second extension mechanism 121 are extendable track structures driven internally by electromagnetic force, pulleys, sprockets, or gears. Drive shafts 153 and 156 are respectively connected to the internal structures of the first extension mechanism 111 and the second extension mechanism 121. During operation, the rotation generated by drive shafts 153 and 156 is converted into the extension and retraction movements of the first extension mechanism 111 and the second extension mechanism 121 through electromagnetic force, pulleys, sprockets, or gears.

[0117] like Figure 2 and Figure 4 As shown, the battery swapping device 1 in this embodiment further includes a first transmission motor 151 and a second transmission motor 154, both of which are connected below the turntable 13. The first transmission motor 151 directly or indirectly drives the first extension mechanism 111, and the second transmission motor 154 directly or indirectly drives the second extension mechanism 121. Wherein, as... Figure 4 As shown, the first transmission motor 151 is connected to the drive shaft 153 via a reversing device 152, thereby driving the first extension mechanism 111 to move. The second transmission motor 154 is connected to the drive shaft 156 via a reversing device 155, thereby driving the second extension mechanism 111 to move. The reversing devices 152 and 155 can have internal structures such as bevel gears, enabling a 90-degree switch between the motion axes of the first and second transmission motors 151 and 154, which then drive the first extension mechanism 111 and the second extension mechanism 121 via the drive shafts 153 and 156.

[0118] In this embodiment, the battery swapping device 1 further includes a limit sensor, which can be a limit switch or a distance sensor, etc. The limit sensor can be installed on the non-moving part of the first extension mechanism 111 to detect the moving distance or position of the moving part of the first extension mechanism. Alternatively, the limit sensor can be installed on the turntable 13 to detect the moving distance or position of the moving part of the first extension mechanism. The limit sensor is used to detect the extension distance of the first extension mechanism 111 and the second extension mechanism 121, and the first transmission motor 151 and the second transmission motor 154 adjust the extension distance of the first extension mechanism 111 and the second extension mechanism 121 respectively. For example, when the detected extension distance of the first extension mechanism 111 is less than a set distance, the first transmission motor 151 continues to rotate to reach the preset position, thereby realizing closed-loop control and ensuring the precise positioning of the first extension mechanism 111 and the second extension mechanism 121.

[0119] In this embodiment, the battery swapping device 1 also includes a tilting position sensor. The tilting position sensor detects the tilting angles of the first tilting part 11 and the second tilting part 12, and adjusts these tilting angles via the tilting motor 157. The tilting position sensor can be a limit switch, an angle sensor, a linear encoder, etc. Specifically, the tilting position sensor can be mounted on the base 14 to detect the tilting angle of the turntable 13, thereby obtaining the tilting angles of the first tilting part 11 and the second tilting part 12. For example, if the detected tilting angle of the turntable 13 is less than the set tilting angle, the tilting motor 157 continues to rotate to reach the preset position, thus achieving closed-loop control and ensuring the precise positioning of the first tilting part 11 and the second tilting part 12.

[0120] like Figure 2 and Figure 4 As shown, the flipping drive device of this embodiment includes a flipping motor 157 and a gear set 16. The gear set 16 includes at least an input gear 161 and an output gear 162, which are meshed with each other. The flipping motor 157 directly or indirectly drives the input gear 161 to rotate. The first flipping part 11 and the second flipping part 12 are fixedly connected to the output gear 162 via a flipping shaft and rotate with the output gear 162. The input gear 161 and the output gear 162 can directly output to each other or be driven by other gears. The flipping motor 157 is connected to the drive shaft 159 via a converter 158, thereby driving the gear set 16 to rotate.

[0121] like Figure 6 and Figure 7 As shown, charging compartment A is equipped with charging device 20. Figure 5As shown. The charging device 20 includes a floating disk 21 that carries the battery and an electrical connector 22 that forms an electrical connection with the battery pack 4 to charge and discharge the battery pack 4. In this embodiment, the floating disk 21 can be a flat plate structure, a frame structure, or other structural components that can support the battery pack and float along a first direction. The charging assembly 2 also includes a fixed disk 28 located below the floating disk 21 to support and carry the floating disk 21. The charging compartment A is composed of a charging frame, which is composed of multiple horizontal and vertical beams. The floating disk 21 can also be directly mounted on the charging frame.

[0122] like Figure 6 and Figure 7 As shown, the charging device 20 in this embodiment also includes an electrical connector 22 for forming an electrical connection with the battery pack 4 to charge and discharge the battery pack 4. In this embodiment, the electrical connector 22 is located above the floating disk 21 in the charging compartment A, and can be electrically connected to the battery pack 4 in the vertical direction to charge and discharge the battery pack. The electrical connector 22 can be directly mounted on the crossbeam of the charging frame via a mounting base. The electrical connector 22 includes a charging head 221 and a terminal (not shown in the figure, but may actually be located on the top or side of the electrical connector 22). The charging head 221 is used to form an electrical connection with the charging port of the battery pack 4, and the terminal is used to connect to an external charging module to charge the battery pack 4.

[0123] The process of placing the depleted battery pack 4, located in the second position, into charging compartment A for charging includes:

[0124] Move the depleted battery pack 4 into the floating disk 21 inside the charging compartment A;

[0125] The control electrical connector moves towards the depleted battery pack 4 and forms an electrical connection.

[0126] like Figure 5 As shown, a linkage mechanism 23 is provided between the floating disk 21 and the electrical connector 22, allowing the floating disk 21 to float up and down under the gravity of the battery pack 4. The electrical connector 22 is slidably mounted on the mounting base 24 and installed in the charging compartment A via the mounting base 24. Figure 3 As shown, the charging device 20 in this embodiment also includes a linkage mechanism 23, which is connected to the floating disk 21 and the electrical connector 22 respectively. When the floating disk 21 generates a first displacement along the first floating direction V, the linkage mechanism 23 drives the electrical connector 22 to move a second displacement along the direction closer to the battery pack 4, so that the electrical connector 22 and the battery pack 4 form an electrical connection.

[0127] In this embodiment, the floating disk 21 is moved by the gravity of the battery pack 4. By setting a linkage mechanism 23 between the floating disk 21 and the electrical connector 22, the electrical connector 22 is moved toward the battery pack 4 to form an electrical connection. That is, the electrical connection is achieved by the gravity of the battery pack 4 itself, without the need for additional power to drive the electrical connector 22 to move. Moreover, this linkage method can be applied to electrical connections in various orientations of the battery pack 4.

[0128] The electrical connector 22 of this invention is linked to the battery pack 4 via a linkage mechanism 23, thus no longer being a fixed connector 22. Therefore, the moving connector 22 does not need to be in the same direction as the battery pack 4, and its orientation can be arbitrary. The linkage mechanism 23 is activated by changes in the load on the floating disk 21, allowing the connector 22 to respond promptly and connect to the battery pack 4. The power for the movement of the connector 22 comes from the gravity of the battery pack 4, eliminating the need for external drive and simplifying the internal structure of the charging device 20.

[0129] As described above, the linkage mechanism is used to move the electrical connector 22 toward or away from the battery when the floating disk 21 floats up and down; placing the depleted battery pack 4 in the second position into the charging compartment A for charging includes:

[0130] The second extension mechanism 121 places the depleted battery pack 4 from the third position onto the floating disk 21 inside the charging compartment A and aligns the electrical connector and electrical connector 22 of the battery pack 4.

[0131] The floating disk 21 floats downwards by the first displacement under the gravity of the battery pack 4;

[0132] The linkage mechanism 23 drives the electrical connector 22 to move a second displacement toward the battery pack 4 and forms an electrical connection with the battery pack 4.

[0133] The process of removing a fully charged battery pack 4 from charging compartment A includes:

[0134] The second extension mechanism 121 is aligned to move the fully charged battery pack 4 out of the floating disk 21 in the charging compartment A and move it to the fourth position;

[0135] The floating disk 21 floats upward by a first displacement under the action of the reset element 26;

[0136] The linkage mechanism 23 drives the electrical connector 22, and with the help of the reset element 27, moves it a second displacement away from the battery pack 4 and disengages from the battery pack 4.

[0137] When the battery pack 4 is installed on an electric vehicle, the battery pack 4 and the electrical connector 22 on the electric vehicle are generally connected horizontally. The horizontal electrical connection is suitable for the electric vehicle during operation, especially under conditions of severe vehicle shaking, in order to provide a reliable and stable electrical connection. However, when the battery pack 4 is unloaded from the electric vehicle and connected to the electrical connector located on the inside horizontally in the charging compartment for charging and discharging, the battery pack needs to be rotated 180 degrees horizontally to align with the electrical connector in the charging compartment. For larger battery packs, this requires a large battery swapping space and is not suitable for situations with a small battery swapping area. In this embodiment, the electrical connector 22 located above the floating disk only requires the battery pack 4 to be rotated 90 degrees vertically to achieve charging and discharging, without occupying a large battery swapping space. At the same time, the gravity of the battery pack 4 is used to achieve the electrical connection between the battery pack 4 and the electrical connector 22, eliminating the need for an additional drive mechanism. The electrical connection between the two is achieved simply by placing the battery pack on the floating disk, eliminating the complex operation of aligning the electrical connector and the battery pack. This results in higher charging docking efficiency and lower charging costs.

[0138] In other embodiments, the electrical connector 22 can also be adaptively located on the side or bottom of the charging compartment to accommodate different orientations of the socket end of the battery pack 4 placed in the charging compartment A. Specifically, the linkage mechanism 23 in this embodiment can be used, which only requires adjusting the position of the electrical connector 22 and moving it towards the battery under the gravity of the battery pack 4.

[0139] Preferably, the linkage mechanism includes a sliding mechanism 233, a first traction member 231, and a second traction member 232. The first traction member 231 is connected to the sliding mechanism 233 and the floating disk 21, respectively. The second traction member 232 is connected to the electrical connector 22 and the mounting base 24, respectively. The electrical connector 22 is mounted on the mounting base 24 and moves relative to the mounting base 24. The second traction member 232 is slidably connected to the sliding mechanism 232.

[0140] The linkage mechanism 23 in this embodiment includes a sliding mechanism 233, a first traction member 231, and a second traction member 232. The first traction member 231 is connected to the sliding mechanism 233 and the floating disk 21, respectively. The second traction member 232 is connected to the electrical connector 22 and the mounting base 24, respectively. The electrical connector 22 is mounted on the mounting base 24 and moves relative to the mounting base 24. The second traction member 232 is slidably connected to the sliding mechanism 233. This constitutes the structure of a movable pulley.

[0141] The first traction member 231 and the second traction member 232 can be structures such as wire ropes or belts. The sliding mechanism 233 can be a structure such as pulleys or sliders. The second traction member 232 slides below the sliding mechanism 233. The second traction member 232 not only slides relative to the sliding mechanism 233 but also moves up and down with the sliding mechanism 233. The first traction member 231 is directly fixed to the sliding mechanism 233 and therefore moves with it. Thus, regardless of the direction of movement, the movement distance of the second traction member 232 includes both the sliding distance relative to the sliding mechanism 233 and the distance it moves with the sliding mechanism 233, while the first traction member 231 only includes the distance it moves with the sliding mechanism 233. Therefore, the movement distance of the second traction member 232 is twice that of the first traction member 231. Meanwhile, one end of the second traction member 232 is fixed to the mounting base 24 and does not move. Therefore, the electrical connector 22 connected to the other end of the second traction member 232 achieves a movement distance of twice that of the first traction member 231, thereby achieving a second displacement greater than the first displacement.

[0142] The process of placing the depleted battery pack 4, located in the second position, into charging compartment A for charging includes:

[0143] The second extension mechanism 121 moves the depleted battery pack 4 from the third position into the floating disk 21 inside the charging compartment A;

[0144] The first traction component 231 is driven by the floating disk 21 and pulls the sliding mechanism 233 to move downward together;

[0145] The second traction member 232 is driven downward by the sliding mechanism 233, and at the same time, it slides along with the sliding mechanism 233. One end of the second traction member is fixed, and the other end pulls the electrical connector 22 to achieve a movement distance twice that of the floating disk 21.

[0146] Electrical connector 22 moves toward the depleted battery pack 4 and forms an electrical connection.

[0147] Removing the fully charged battery pack 4 from charging compartment A includes:

[0148] The second extension mechanism 121 moves the fully charged battery pack 4 out of the floating disk 21 in the charging compartment A and moves it to the fourth position;

[0149] The floating disk 21 floats upward by a first displacement under the action of the reset element 26;

[0150] At this time, the first traction member 231 and the second traction member 232 are released, and thus move along with the floating disk 21 and the electrical connection 22;

[0151] Under the action of the reset element 27, the electrical connector 22 moves a second displacement away from the battery pack 4 and disengages from the battery pack 4. At this time, one end of the second traction member 232 moves upward with the electrical connector 22. The second traction member 232 moves upward with the sliding mechanism 233 and slides relative to the sliding mechanism 233. The sliding mechanism 233 pulls the upper end of the first traction member 231 upward.

[0152] In this embodiment, the battery pack 4 is rotated while moving towards the charging compartment A or the electric vehicle 3; or the battery pack 4 is rotated and then moved towards the charging compartment A or the electric vehicle 3; or the battery pack 4 is rotated and then moved towards the charging compartment A or the electric vehicle 3.

[0153] Example 2

[0154] The difference between this embodiment and Embodiment 1 is that this embodiment includes a battery pick-and-place mechanism. The battery pick-and-place mechanism and the flipping mechanism 10 can be the same or different mechanisms. In this case, the battery pack 4 is not picked up or placed through the first extension mechanism 111 and the second extension mechanism 121, but through the battery pick-and-place mechanism. The battery pick-and-place mechanism can be an independent mechanism located externally, which removes the battery pack from the electric vehicle or charging compartment and places it on the battery swapping equipment by hoisting, clamping, or lifting the battery pack with a telescopic fork, or removes the battery pack from the battery swapping equipment and places it in the electric vehicle or charging compartment. For example, it can be a telescopic mechanism located in the electric vehicle 3 or a conveying mechanism located in the charging compartment A. In this case, the flipping mechanism 10 only needs to be aligned to realize the transfer of the battery pack 4. The battery pick-and-place mechanism can also be a separate mobile transport mechanism responsible for moving the battery pack 4 between the flipping mechanism 10 and the charging compartment A or the charging vehicle.

[0155] The battery pack 4 is retrieved from or placed in the electric vehicle 3 or the charging compartment A by setting up a battery retrieval and placement mechanism; wherein, retrieving the depleted battery pack 4 from the electric vehicle 3 and placing it in the first position includes: controlling the battery retrieval and placement mechanism to retrieve the depleted battery pack 4 from the electric vehicle 3 and place it in the first position on the flipping mechanism 10.

[0156] Alternatively, removing a fully charged battery pack 4 from charging compartment A and placing it in the third position includes: controlling the battery loading and unloading mechanism to remove a fully charged battery pack 4 from charging compartment A and place it in the third position of the flipping mechanism 10.

[0157] The battery pack in this invention requires less space to flip, and the flipping mechanism is structurally significantly smaller compared to planar rotating battery swapping devices. Therefore, the battery swapping method of this invention can complete the loading and unloading of larger battery packs within a charging station with a smaller space and structure. This simplifies the battery swapping process and increases the swapping speed. Furthermore, it allows for battery replacement of electric vehicles using a single large battery pack within a smaller battery swapping station footprint, thereby reducing battery pack costs and facilitating widespread adoption.

[0158] While specific embodiments of the present invention have been described above, those skilled in the art should understand that these are merely illustrative examples, and the scope of protection of the present invention is defined by the appended claims. Those skilled in the art can make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, but all such changes and modifications fall within the scope of protection of the present invention.

Claims

1. A battery swapping method, characterized in that, The battery swapping method utilizes a flipping mechanism to flip a depleted or fully charged battery pack. The flipping mechanism includes a first flipping section and a second flipping section. The first flipping section carries a battery pack located at a first or fourth position, and the second flipping section carries a battery pack located at a second or third position. The first and second flipping sections are arranged perpendicularly to each other. The battery swapping method includes: Remove the depleted battery pack from the electric vehicle and place it in the first position on the flipping mechanism; The drive flipping mechanism flips the removed depleted battery pack 90 degrees from the first position along the first direction to the second position; The depleted battery pack in the second position is placed into the charging compartment for charging. The charging compartment is equipped with a floating disk for carrying the battery and an electrical connector for electrically connecting with the battery pack to charge and discharge the battery pack. Placing the depleted battery pack in the second position into the charging compartment for charging includes: Move the depleted battery pack into the floating disk inside the charging compartment; The control connector moves toward the depleted battery pack and forms an electrical connection; And / or remove the fully charged battery pack from the charging compartment and place it in the third position of the flipping mechanism; The drive flipping mechanism flips the fully charged battery pack taken out from the third position 90 degrees along the second direction to the fourth position; Place the fully charged battery pack, located in the fourth position, into the electric vehicle. By incorporating an extension mechanism on the flipping mechanism, the battery pack located on the electric vehicle or charging compartment can be placed or removed. A linkage mechanism is provided between the floating disk and the electrical connector. The linkage mechanism includes a sliding mechanism, a first traction member, and a second traction member. The first traction member is connected to the sliding mechanism and the floating disk, respectively. The second traction member is connected to the electrical connector and a mounting base, respectively. The electrical connector is mounted on the mounting base and moves relative to the mounting base. The second traction member is slidably connected to the sliding mechanism.

2. The battery swapping method as described in claim 1, characterized in that, Removing a depleted battery pack from an electric vehicle and placing it in a first position includes: controlling an extension mechanism to extend toward the electric vehicle; controlling the extension mechanism to lift the depleted battery pack located inside the electric vehicle; and controlling the extension mechanism to retract so that the depleted battery pack reaches a first position on a flipping mechanism. Alternatively, removing a fully charged battery pack from the charging compartment and placing it in the third position includes: controlling the extension mechanism to extend towards the charging compartment; controlling the extension mechanism to lift the fully charged battery pack located in the charging compartment; and controlling the extension mechanism to retract so that the fully charged battery pack reaches the third position on the flipping mechanism.

3. The battery swapping method as described in claim 1, characterized in that, Controlling the removal of a depleted battery pack to flip from a first position to a second position along a first direction includes: Determine whether the battery pack is located in the first position; If so, the flipping mechanism is controlled to flip the depleted battery pack along the first direction; Determine whether the battery pack has reached the second position; If so, the flipping mechanism is controlled to stop flipping the depleted battery pack.

4. The battery swapping method as described in claim 3, characterized in that, in, The battery swapping method also includes: The system checks whether the first and second flipping parts have rotated to the correct positions. If they have rotated to the correct positions, the system starts moving the battery pack. If they have not rotated to the correct positions, the system continues to rotate. And / or detect whether the battery pack has moved into place on the first or second flipping part. If it has moved into place, start rotating the first or second flipping part. If it has not moved into place, continue moving.

5. The battery swapping method as described in claim 4, characterized in that, The floating disk can float up and down under the weight of the battery pack. The linkage mechanism is used to drive the electrical connector to move closer to or away from the battery when the floating disk floats up and down. Placing the depleted battery pack in the charging compartment for charging, located in the second position, includes: Place the depleted battery pack on the floating tray inside the charging compartment and align the electrical connectors and terminals of the battery pack. The floating disk floats downwards by a first displacement under the influence of the battery's gravity. The linkage mechanism drives the electrical connector to move a second displacement toward the battery pack and forms an electrical connection with the battery pack.

6. The battery swapping method as described in claim 5, characterized in that, The floating disk is equipped with a reset element, and removing the fully charged battery pack from the charging compartment and placing it in the third position includes: The fully charged battery pack is removed from the floating disk inside the charging compartment and placed in the third position of the flipping mechanism; The floating disk floats upward by a first displacement under the action of the reset element; The linkage mechanism drives the electrical connector to move a second displacement away from the battery pack and detach it from the battery pack.

7. The battery swapping method as described in claim 5, characterized in that, The second displacement is greater than the first displacement.

8. The battery swapping method as described in claim 1, characterized in that, The process of placing the depleted battery pack, located in the second position, into the charging compartment for charging includes: Move the depleted battery pack into the floating disk inside the charging compartment; The first traction member is driven by the floating disk and pulls the sliding mechanism; The second traction member is driven by the sliding mechanism and pulls the electrical connector; The electrical connector moves toward the depleted battery pack and forms an electrical connection.

9. The battery swapping method as described in claim 1, characterized in that, Removing the fully charged battery pack from the charging case includes: Remove the fully charged battery pack from the floating disk inside the charging compartment; The floating disk floats upward by a first displacement under the action of the reset element; The first and second traction components move in accordance with the floating disk and the electrical connector; The electrical connector moves a second displacement away from the battery pack and disengages from the battery pack.

10. The battery swapping method according to any one of claims 1-9, characterized in that, The battery pack can be rotated while moving it toward the charging compartment or electric vehicle; or the battery pack can be rotated and then moved toward the charging compartment or electric vehicle; or the battery pack can be rotated and then moved toward the charging compartment or electric vehicle.

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