Battery replacement device and method for unmanned aerial vehicle

Abstract

The application provides a battery replacing device and method for a UAV, comprising a UAV body, a battery compartment charging assembly, an X-axis linear movement assembly, a Z-axis linear movement assembly, and an end effector assembly. The battery replacing system provided by the application has the advantages of fewer degrees of freedom, simpler and more reliable structure, convenient debugging, higher battery replacing efficiency, and the like, and meets the needs of reliable battery replacing for small UAVs, high battery replacing efficiency, and high-frequency operation.

Description

Technical Field

[0001] This invention belongs to the field of unmanned aerial vehicle (UAV) technology, specifically relating to a battery swapping device and method for UAVs. Background Technology

[0002] A drone nest is a dedicated parking area specifically designed for drones. It allows drones to be deployed to the work site, solving the problem of manually carrying drones. The biggest advantage of on-site deployment is enhanced emergency operation capabilities, and operational efficiency is significantly improved. When not in use, the drones standby inside the drone nest. When the work area or airport door is opened, the drones automatically fly out to perform their tasks. A drone nest typically includes the nest itself, an automatic centering mechanism, a lifting platform, a power supply system, a weather station, a UPS, and industrial air conditioning. Its main functions usually include drone parking, autonomous power supply, autonomous inspection, one-button takeoff, real-time data transmission, and precise landing.

[0003] Currently, the main way to recharge drone nests in the industry is through battery charging. Battery charging time is generally 60 minutes, and the drone's single flight time is basically 45 minutes. Recharging cannot meet the requirements of uninterrupted drone operation in real time.

[0004] In the event of a sudden emergency operation, this power replenishment method cannot meet the operational requirements and cannot achieve uninterrupted flight. Currently, some manufacturers are conducting direct battery swapping operations on large drones to increase the frequency of operations. The battery swapping mechanism uses a robotic arm for battery swapping, which is costly. At the same time, the battery swapping action is too cumbersome, has too many structural degrees of freedom, and the application scenarios of large drones are locally limited, making them unsuitable for places with limited space. The demand for battery swapping for small aircraft with high efficiency and reliability is becoming increasingly strong.

[0005] In response to this situation, it is necessary to invent a battery swapping system for small drones to meet the needs of scenarios with limited space requiring small drone inspections. At the same time, through methods such as structural coupling, reasonable placement of components, and optimized battery swapping control logic, this battery swapping system has significant advantages over traditional battery swapping solutions, including fewer degrees of freedom, simpler and more reliable structure, convenient debugging, and higher battery swapping efficiency. It meets the requirements of reliable battery swapping, high battery swapping efficiency, and high-frequency operation for small drones. Summary of the Invention

[0006] Purpose of the invention: To address the aforementioned prior art, a battery swapping device and method for unmanned aerial vehicles (UAVs) are proposed.

[0007] Technical solution:

[0008] A battery swapping device for a drone includes a drone body, a battery compartment charging assembly, an X-axis linear motion assembly, a Z-axis linear motion assembly, and an end effector assembly.

[0009] The X-axis linear motion assembly includes a first fixed plate, an X-axis motor is provided on one side of the first fixed plate, the drive end of the X-axis motor is driven to connect to the X-axis lead screw through a first coupling, a first lead screw nut is driven to connect to the X-axis lead screw, and the Z-axis linear motion assembly is connected to the lead screw nut. Guide rails A are provided on both the upper and lower sides of the first fixed plate, and the Z-axis linear motion assembly is slidably connected to the guide rails A.

[0010] The Z-axis linear motion assembly includes a second fixed plate, a Z-axis motor is provided above the second fixed plate, the drive end of the Z-axis motor is driven to connect to the Z-axis lead screw through a second coupling, a second lead screw nut is driven to connect to the Z-axis lead screw, an adapter plate is connected to the second lead screw nut, and guide rails B are also provided on both sides of the second fixed plate, and the two sides of the second fixed plate are slidably connected to the guide rails B.

[0011] The battery compartment charging assembly includes a supporting beam on which a battery compartment bracket is provided. Multiple battery compartments are provided inside the battery compartment bracket through a partition. Each of the multiple battery compartments is equipped with a proximity sensor and a charging PCB board. The charging PCB board is in contact with the drone battery.

[0012] The end effector assembly includes an end effector gripper connected to the underside of the adapter plate, and the drive end of the end effector gripper is connected to the drone battery.

[0013] Preferably, the battery swapping device further includes a drone propeller alignment assembly, which includes two sets of parallel uprights on the left and right, and a cover is connected to the top of the four uprights.

[0014] Preferably, both the first fixing plate and the second fixing plate are provided with a cable chain on one side, and the cable chain contains a cable.

[0015] Preferably, each of the multiple battery compartments is provided with a protrusion above it, the protrusion being slidably connected to a slide groove, the slide groove being located above the drone battery; a torsion spring is connected to the bottom of the multiple battery compartments and to the battery compartment bracket, the driving end of the torsion spring being connected to a slider, one end of the slider penetrating the partition and contacting a slot, the slot being located below the drone battery.

[0016] Preferably, the drive end of the end-effector gripper is symmetrically connected to a gripper bracket, and each end of the two gripper brackets is connected to a clamping block, and each side of the two clamping blocks is connected to a push-mounted rubber pad.

[0017] Preferably, the side of the clamping block that contacts the drone battery is connected to a clamping block pad.

[0018] Preferably, one of the clamping blocks is also connected to a power on / off button shaft.

[0019] A method for swapping drone batteries:

[0020] 1): Drive the X-axis motor and Z-axis motor to move the power button at the end of the end effector assembly. The power button contacts the switch connected to the drone, turning off the drone.

[0021] 2): The end effector assembly drives the two gripper brackets to move. The two gripper brackets clamp the clip at the end of the drone battery. The X-axis motor drives the end effector assembly to pull the drone battery out a distance. Because the clip of the drone battery is always clamped at this time, it is not safe to move it. After pulling the drone battery out a distance, the clip is released and the drone battery body is clamped again.

[0022] 3): Drive the X-axis motor and Z-axis motor, and the two gripper brackets move the drone battery to the set position and place it in the battery compartment. Then, push the drone battery into the battery compartment using the push pad.

[0023] 4): The charging PCB board in the battery compartment charges the drone battery;

[0024] 5): Use the two sets of parallel poles on the left and right to return the drone's propellers to their original positions;

[0025] 6): After charging is complete, drive the X-axis motor and Z-axis motor, and the two gripper brackets will remove the drone battery from the battery compartment and install it back into the drone. Then, press the power button to connect the switch to the drone and turn it on.

[0026] Beneficial effects: Through structural coupling and battery swapping control logic, this battery swapping system has significant advantages over traditional battery swapping solutions, such as fewer degrees of freedom, simpler and more reliable structure, convenient debugging, and higher battery swapping efficiency. It meets the requirements of reliable battery swapping, high battery swapping efficiency, and high-frequency operation for small UAVs. Attached Figure Description

[0027] Figure 1 This is the assembly drawing of the battery swapping device;

[0028] Figure 2 This is a schematic diagram of the battery compartment's frame for storing batteries;

[0029] Figure 3 This is a schematic diagram of a 2-axis linear transmission structure;

[0030] Figure 4(a) is a schematic diagram of the structure of the drone without the end effector holding the drone battery;

[0031] Figure 4(b) is a schematic diagram of the end effector holding the UAV battery;

[0032] Figure 5 This is a schematic diagram of the battery swapping process using a battery swapping device;

[0033] Figure 6 This is a schematic diagram of the modular design structure of the battery swapping device;

[0034] Figure 7 This is a flowchart of the battery swapping operation control process for the battery swapping device.

[0035] Figure 8 This is a partial schematic diagram of the protruding block of the battery swapping device;

[0036] Figure 9 This is a schematic diagram of the slider position of the switching device.

[0037] In the diagram: 1. Drone body; 2. Battery compartment charging assembly; 21. Support beam; 22. Charging PCB board; 23. Proximity sensor; 25. Drone battery; 26. Battery compartment bracket; 28. X-axis linear motion assembly; 3. Z-axis linear motion assembly; 4. End effector assembly; 5. First fixed plate; 30. X-axis motor; 31. First coupling; 32. X-axis lead screw; 33. Guide rail A; 34. Second fixed plate; 40. Guide rail B; 41. Z-axis lead screw; 42. Z-axis motor; 43. Second lead screw nut; 44. Adapter plate; 45. End effector assembly; 51. Clamping block pad; 52. Clamping block; 53. Push-mount pad; 54. Power button shaft; 55. Gripper bracket; 56. End effector gripper; 6. Drone propeller alignment assembly. Detailed Implementation

[0038] The invention will now be further explained with reference to the accompanying drawings.

[0039] like Figure 1 The device can be mainly divided into modules such as the drone body, battery compartment charging component, linear motion component, and end effector component. The 3-X-axis linear motion component drives the 33-X-axis lead screw to rotate through the 31-X-axis motor, thereby enabling the 4-Z-axis linear motion component to translate along the X-axis. Similarly, the 4-Z-axis linear motion component enables the 5-end effector component to translate along the Z-axis. Through the coupling of the 3-X-axis linear motion component and the 4-Z-axis linear motion component, the 5-end effector component can move in both the X and Z directions.

[0040] Furthermore, the 6-UAV propeller alignment component aligns the UAV blades, preventing the 5-end effector component from damaging the UAV blades during battery swapping. This structure cleverly utilizes two plastic rods and a retractable hull structure to align the UAV blades, achieving low cost and reliability while effectively saving the need for a separate blade alignment mechanism.

[0041] Furthermore, the charging components for the 2-battery compartment are described, such as... Figure 2 The battery compartment assembly features four battery slots arranged vertically. This design meets the requirements of drone battery swapping operations while reducing one degree of freedom. The 5-end effector assembly does not need to move in the Y-axis direction, reducing the cost of the battery swapping system and improving its reliability. Each battery slot is equipped with a 23-proximity sensor. When a drone battery is in a slot, a signal is triggered, allowing the control system to monitor the battery slot status in real time. When the 5-end effector assembly delivers a battery to the battery compartment for charging, it can identify empty slots, preventing interference with battery storage. Furthermore, when the drone battery is in a slot, it is charged via a 22-charging PCB board. This PCB board features overcharge and overload protection and can identify the battery's charge level, effectively recognizing a fully charged battery and communicating this information to the control system. This prevents undercharged batteries from being installed on the drone, which could affect its operational range. In addition, the battery compartment is equipped with a protruding block to prevent positional displacement when the 53 push-mount rubber pad pushes the battery, which would affect the clamping accuracy of the 26-drone battery during battery swapping. A torsion spring is also included to ensure the slider fits snugly against the groove of the 26-drone battery, preventing poor contact between the battery and the 22-charging PCB board during charging. When the 5-end effector assembly removes the battery from the battery compartment, as it moves to the designated battery clamping position, the 52-clamping block pushes the slider away during the clamping process. The slider rotates around the torsion spring, disengaging from the 26-drone battery's locking position. When the 5-end effector assembly leaves the battery compartment with the 26-drone battery clamped, the slider resets under the action of the torsion spring. Similarly, when reinstalling the 26-drone battery back into the battery compartment, the slider is pushed away to limit battery installation. This design solves the problem of limiting the 26-drone battery's position without requiring additional action to contact the mechanical limit, thus saving time in releasing the limit and improving battery swapping efficiency.

[0042] Further, the 5-end effector assembly is described in Figure 4. The 55-gripper bracket is fixed to the 56-end effector gripper by screws. The 52-clamping block is fixed to the 55-gripper bracket. The 51-clamping block rubber pad and the 53-push-in rubber pad are fixed to the 52-clamping block. The 54-power-on / off button shaft is fixed to the 52-clamping block. A spring connects the 54-power-on / off button shaft and the 52-clamping block, providing a buffer and protecting the battery power-on / off button. The lower part of the 52-clamping block has a boss structure to prevent interference when the 5-end effector assembly clamps the 26-UAV battery lock. The design of the 51-clamping block rubber pad prevents damage to the 26-UAV battery. The movement of the 56-end effector gripper drives the corresponding bracket to move, meeting the operational requirements of battery replacement. This invention integrates functions such as battery power-on / off, battery lock release, battery clamping, and battery pushing. Its advantage lies in its high integration; all action switching is completed in one component. See details... Figure 5 The workflow diagram is designed with fewer parts, but achieves more functions, thus improving the efficiency of battery swapping operations.

[0043] Furthermore, such as Figure 6 The modular design concept runs through the invention of this battery swapping system. The modular design facilitates assembly, debugging, and maintenance, effectively reducing costs. In summary, this battery swapping system, through the coupling of motion structures and battery swapping control methods, meets the requirements of battery power-on / off and battery removal / installation while using fewer degrees of freedom, resulting in lower costs, higher battery swapping efficiency, and identification of the battery compartment's position status.

[0044] A method for swapping a drone battery includes the following steps:

[0045] 1): Drive the X-axis motor and Z-axis motor to move the power switch shaft at the end of the end effector assembly, and the power switch shaft contacts the switch of the drone;

[0046] 2): The end effector assembly drives the two gripper brackets to move, and the two gripper brackets clamp the end of the drone battery;

[0047] 3): Drive the X-axis motor and Z-axis motor, and the two gripper brackets move the drone battery to the set position and push it into the battery compartment;

[0048] 4): The charging PCB board in the battery compartment charges the drone battery;

[0049] 5): After charging is complete, drive the X-axis motor and Z-axis motor, and the two gripper brackets will remove the drone battery from the battery compartment and install it back into the drone.

[0050] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A battery swapping device for unmanned aerial vehicles (UAVs), characterized in that, Includes the drone body (1), battery compartment charging assembly (2), X-axis linear motion assembly (3), Z-axis linear motion assembly (4), and end effector assembly (5); The X-axis linear motion assembly (3) includes a first fixed plate (30), an X-axis motor (31) is provided on one side of the first fixed plate (30), the drive end of the X-axis motor (31) is driven to connect to the X-axis lead screw (33) through the first coupling (32), the X-axis lead screw (33) is driven to connect to the first lead screw nut, the Z-axis linear motion assembly (4) is connected to the lead screw nut, and the first fixed plate (30) is provided with guide rails A (34) on both the upper and lower sides, the Z-axis linear motion assembly (4) is slidably connected to the guide rails A (34); The Z-axis linear motion assembly (4) includes a second fixed plate (40), a Z-axis motor (43) is provided above the second fixed plate (40), the drive end of the Z-axis motor (43) is driven to connect to the Z-axis lead screw (42) through a second coupling, a second lead screw nut (44) is driven to connect to the Z-axis lead screw (42), an adapter plate (45) is connected to the second lead screw nut (44), and guide rails B (41) are also provided on both sides of the second fixed plate (40), and the two sides of the second fixed plate (40) are slidably connected to the guide rails B (41). The battery compartment charging assembly (2) includes a support beam (21), on which a battery compartment bracket (28) is provided. Multiple battery compartments are provided in the battery compartment bracket (28) through a partition. Each of the multiple battery compartments is provided with a proximity sensor (23) and a charging PCB board (22). The charging PCB board (22) is in contact with the drone battery (26). The end effector assembly (5) includes an end effector gripper (56) connected to the lower part of the adapter plate (45), and the drive end of the end effector gripper (56) is connected to the drone battery (26). Each of the battery compartments has a protrusion (25) above it, the protrusion (25) is slidably connected to a slide groove, the slide groove is opened above the drone battery (26); a torsion spring is connected to the bottom of the battery compartment and to the battery compartment bracket (28), the driving end of the torsion spring is connected to a slider, one end of the slider passes through the partition and is in contact with a slot, the slot is located below the drone battery (26).

2. The battery swapping device for a drone as described in claim 1, characterized in that, The battery swapping device also includes a drone propeller alignment assembly (6), which includes two sets of parallel uprights on the left and right, and a cover is connected above the four uprights.

3. The battery swapping device for a drone as described in claim 1, characterized in that, Both the first fixing plate (30) and the second fixing plate (40) are provided with a drag chain on one side, and the drag chain contains a cable.

4. The battery swapping device for a drone as described in claim 1, characterized in that, The drive end of the end-acting gripper (56) is symmetrically connected to gripper brackets (55), and the ends of the two gripper brackets (55) are connected to clamping blocks (52), and one side of the two clamping blocks (52) is connected to a push-mounted rubber pad (53).

5. A battery swapping device for a drone as described in claim 4, characterized in that, Each clamping block (52) has a clamping block pad (51) connected to the side of the clamping block (52) that contacts the drone battery (26).

6. A battery swapping device for a drone as described in claim 4, characterized in that, One of the clamping blocks (52) is also connected to a power on / off button (54).

7. A battery swapping method applied to a battery swapping device for a drone battery according to any one of claims 1-6, comprising the following steps: 1): Drive the X-axis motor and Z-axis motor to move the power button at the end of the end effector assembly. The power button contacts the switch connected to the drone, turning off the drone. 2): The end effector assembly drives the two gripper brackets to move. The two gripper brackets clamp the clip at the end of the drone battery. The X-axis motor drives the end effector assembly to drag the drone battery a certain distance, then releases the clip and clamps the drone battery body again. 3): Drive the X-axis motor and Z-axis motor, and the two gripper brackets move the drone battery to the set position and place it in the battery compartment. Then, push the drone battery into the battery compartment using the push pad. 4): The charging PCB board in the battery compartment charges the drone battery; 5): Use the two sets of parallel poles on the left and right to return the drone's propellers to their original positions; 6): After charging is complete, drive the X-axis motor and Z-axis motor, and the two gripper brackets will remove the drone battery from the battery compartment and install it back into the drone. Then, press the power button to connect the switch to the drone and turn it on.

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