An intelligent station control system of a heavy truck battery swap station

Abstract

The application discloses an intelligent station control system of a heavy truck battery swap station, which is used for realizing heavy truck battery swap and comprises a station control device in the battery swap station, a station control subsystem, a PLC control subsystem and a vehicle end controller, wherein the station control device in the battery swap station is in communication connection with the station control subsystem, the station control device in the battery swap station is connected with the PLC control subsystem, and the station control device in the battery swap station is controlled by the PLC control subsystem; the vehicle end controller is in communication connection with the station control subsystem, the PLC control subsystem is in communication connection with the station control subsystem, and when the vehicle end controller is disconnected with the station control subsystem in a heavy truck battery swap process, the communication between the vehicle end controller and the station control subsystem is automatically reconnected through the PLC control subsystem. When the vehicle end controller is disconnected with the station control subsystem, the automatic reconnection mechanism is started, the battery swap process is ensured not to be interrupted, and the success rate of battery swap is improved.

Description

Technical Field

[0001] This invention relates to the field of heavy-duty truck battery swapping technology, and more specifically, to an intelligent station control system for a heavy-duty truck battery swapping station. Background Technology

[0002] In the past two years, with the gradual popularization of electric vehicles, heavy-duty trucks, which require significant power during operation, have also begun to move towards the electric era. Simultaneously, heavy-duty truck battery swapping stations, used for swapping batteries for these trucks, have been rapidly established and developed. Currently, heavy-duty truck battery swapping stations mainly face the following problems:

[0003] 1. Currently, the station control system of heavy-duty truck battery swapping stations communicates with devices such as RFID (Radio Frequency Identification), TBOX (Vehicle-mounted Controller), PLC control system, depth camera, and charger through process control to achieve unmanned intelligent battery swapping. However, the communication between the vehicle-mounted controller and the station control system is based on a WIFI wireless network. Due to network instability such as jitter or congestion, when the communication between the vehicle-mounted controller and the station control system is interrupted, there is a risk of battery removal and installation due to battery locking.

[0004] 2. The station control system of the heavy truck swapping station is connected to the depth camera equipment over a long distance via a USB data extension cable and uses enhanced power supply. This may result in signal interference and signal attenuation during long-distance transmission.

[0005] 3. The station control system of heavy-duty truck battery swapping stations obtains the battery code through the vehicle-end controller. There is a problem that the battery code cannot be obtained after battery installation because the vehicle-end controller loses connection with the station control system due to the high voltage during the battery swapping process.

[0006] 4. The station control system of heavy truck battery swapping stations requires the vehicle to engage the handbrake and de-energize before battery swapping can begin. If the driver misoperates by releasing the handbrake or engaging the high voltage during the battery swapping process, the vehicle may slide, bringing a series of risks to the battery swapping process.

[0007] Existing technology discloses an automatic battery swapping system for light truck battery swapping stations, including a station control system, a PLC control system, a positioning mechanism, a lifting mechanism, a stacker crane, and a vision guidance system. The station control system informs the PLC of all vehicle information, charging compartment battery status, and vision guidance results. The PLC control system interacts with the station control system and controls the specific actions of each servo. The positioning mechanism is used to position and align the light truck. The lifting mechanism is used to lift the light truck. The stacker crane removes the old battery from the light truck and replaces it with a new one. The vision guidance system obtains precise image coordinates of the unlocking location and feeds them back to the station control system. This solution is applied to light truck battery swapping, but it fails to solve the technical problem of communication interruptions between the vehicle-side controller and the station control system. Summary of the Invention

[0008] The purpose of this invention is to provide an intelligent station control system for heavy-duty truck battery swapping stations, which solves the technical problem in the prior art where the risk of battery disassembly and installation arises when the communication between the vehicle-end controller and the station control system is interrupted due to battery locking.

[0009] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0010] An intelligent station control system for a heavy-duty truck battery swapping station, used to realize battery swapping for heavy-duty trucks, includes station control equipment, a station control subsystem, a PLC control subsystem, and a vehicle-end controller, wherein:

[0011] The station control equipment within the battery swapping station is communicatively connected to the station control subsystem, and the station control equipment within the battery swapping station is connected to the PLC control subsystem. The station control equipment within the battery swapping station is controlled by the PLC control subsystem.

[0012] The vehicle-end controller is communicatively connected to the station control subsystem, and the PLC control subsystem is communicatively connected to the station control subsystem. When the vehicle-end controller and the station control subsystem are disconnected during the heavy truck battery swapping process, the communication between the vehicle-end controller and the station control subsystem is automatically reconnected through the PLC control subsystem.

[0013] In the above technical means, in order to avoid the disconnection between the vehicle-end controller and the station control system, an automatic reconnection mechanism is adopted in the station control subsystem. If the connection is lost during the battery swapping process, the PLC control subsystem is notified to start the pause mechanism, which solves the disassembly and installation risks caused by battery locking and resolves the problem.

[0014] Furthermore, the heavy-duty truck battery swapping process includes the following steps:

[0015] The vehicle-side controller initiates vehicle authentication to the station control subsystem. After the vehicle authentication is successful, it checks the vehicle status of the handbrake being engaged and the high voltage being lowered. Once the battery swapping conditions are met, the heavy truck begins battery swapping. The heavy truck battery swapping process includes vehicle location identification, detection of the vehicle's handbrake being engaged, detection of the high voltage being lowered, grabbing the vehicle-side battery, and placing the battery on the vehicle. Finally, the heavy truck completes the battery swapping process.

[0016] Furthermore, the communication between the vehicle-side controller and the station control subsystem is monitored through heartbeat detection.

[0017] Furthermore, when the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem, the specific steps include:

[0018] When the vehicle-end controller loses connection with the station control subsystem between the authentication process and the start of battery swapping for the heavy truck, the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem and skips the vehicle authentication process.

[0019] When the disconnection between the vehicle-end controller and the station control subsystem occurs between the start and end of the heavy truck's battery swap, the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem, skipping the vehicle authentication process and the vehicle position identification, vehicle handbrake detection, and high-voltage status detection processes.

[0020] Furthermore, when the disconnection between the vehicle-end controller and the station control subsystem occurs between the start and end of the battery swapping process of the heavy truck, and the current PLC control subsystem is in the process of grabbing or placing the battery on the vehicle end, the battery swapping pause mechanism is activated. After the vehicle-end controller and the station control subsystem resume normal communication, the connection is successfully unlocked and the battery swapping is resumed.

[0021] Furthermore, the station control equipment within the battery swapping station includes a depth camera device, which is communicatively connected to the station control subsystem via an optical fiber.

[0022] Furthermore, the station control equipment within the battery swapping station includes a battery swapping station charger, which is communicatively connected to the station control subsystem. The battery swapping station charger reports the battery compartment battery code to the station control subsystem, replacing the empty battery code uploaded by the vehicle-side controller.

[0023] Furthermore, the battery swapping station charger reports the battery compartment battery code to the station control subsystem, specifically as follows:

[0024] The battery swapping station charger reports the battery compartment battery code to the station control subsystem;

[0025] The station control subsystem requests a vehicle status query from the vehicle controller.

[0026] When the vehicle-end controller receives the vehicle-end status query, if it is powered on after the battery swap is completed, it returns the battery code to the station control subsystem; if it is powered off after the battery swap is completed, the vehicle-end controller disconnects from the station control subsystem, and the station control subsystem receives an empty battery code.

[0027] Replace the empty battery code with the battery code of the battery compartment.

[0028] Furthermore, the PLC control subsystem can also control the station control equipment within the battery swapping station to terminate the battery swapping process if there is a malfunction in the vehicle during the battery swapping process.

[0029] Furthermore, if a vehicle malfunctions during the battery swapping process, the PLC control subsystem will control the station control equipment within the battery swapping station to terminate the battery swapping process. Specifically:

[0030] The station control subsystem requests a vehicle status query from the vehicle controller.

[0031] When the vehicle-end controller receives the vehicle-end status query, if it is in the battery handling stage of the battery swapping process, it returns the current status of whether the vehicle has released the handbrake and whether it has connected to high voltage to the station control subsystem.

[0032] The station control subsystem determines whether the current vehicle has released its handbrake or is connected to high voltage based on the returned status. If the current vehicle is in a state where the handbrake is released or high voltage is connected, the subsystem notifies the PLC control subsystem to terminate the battery swapping operation. The PLC control subsystem then controls the station control equipment within the battery swapping station to terminate the battery swapping process. If the current vehicle is not in a state where the handbrake is released or high voltage is connected, the battery swapping operation continues.

[0033] Compared with the prior art, the beneficial effects of the technical solution of the present invention are:

[0034] This invention enables an automatic reconnection mechanism when the vehicle-side controller and the station control subsystem are disconnected, ensuring that the battery swapping process is not interrupted and improving the success rate of battery swapping. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the intelligent station control system for a heavy-duty truck battery swapping station provided in an embodiment of the present invention.

[0036] Figure 2 This is a schematic diagram of the communication connection when the vehicle-side controller and the station control subsystem are disconnected, as provided in an embodiment of the present invention.

[0037] Figure 3 This is a schematic diagram of the monitoring process of the vehicle-side controller and station control subsystem provided in an embodiment of the present invention.

[0038] Figure 4 This is a schematic diagram illustrating the communication connection between the station control subsystem and the depth camera device provided in an embodiment of the present invention.

[0039] Figure 5 A schematic diagram illustrating the workflow of a depth camera device provided in an embodiment of the present invention.

[0040] Figure 6 This invention provides a schematic diagram of the communication connection when the station control subsystem acquires the battery code, as shown in the embodiment of the invention.

[0041] Figure 7 This invention provides a schematic diagram of the process for the station control subsystem to obtain the battery code in an embodiment of the present invention.

[0042] Figure 8 This invention provides a schematic diagram of the communication connection for terminating the battery swapping process using a PLC control subsystem, as shown in the embodiment of the invention.

[0043] Figure 9 This invention provides a schematic flowchart of the PLC control subsystem's process for terminating the battery swapping process in an embodiment of the invention. Detailed Implementation

[0044] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent.

[0045] To better illustrate this embodiment, some parts in the accompanying drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions.

[0046] It will be understood by those skilled in the art that certain well-known structures and their descriptions may be omitted in the accompanying drawings.

[0047] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0048] Example 1

[0049] This embodiment provides an intelligent station control system for a heavy-duty truck battery swapping station, used to realize battery swapping for heavy-duty trucks, such as... Figure 1 As shown, it includes the station control equipment within the battery swapping station, the station control subsystem, the PLC control subsystem, and the vehicle-end controller, wherein:

[0050] The station control equipment within the battery swapping station is communicatively connected to the station control subsystem, and the station control equipment within the battery swapping station is connected to the PLC control subsystem. The station control equipment within the battery swapping station is controlled by the PLC control subsystem.

[0051] The vehicle-end controller is communicatively connected to the station control subsystem, and the PLC control subsystem is communicatively connected to the station control subsystem. When the vehicle-end controller and the station control subsystem are disconnected during the heavy truck battery swapping process, the communication between the vehicle-end controller and the station control subsystem is automatically reconnected through the PLC control subsystem.

[0052] In a further embodiment, the heavy-duty truck battery swapping includes the following steps:

[0053] The vehicle-side controller initiates vehicle authentication to the station control subsystem. After the vehicle authentication is successful, it checks the vehicle status of the handbrake being engaged and the high voltage being lowered. Once the battery swapping conditions are met, the heavy truck begins battery swapping. The heavy truck battery swapping process includes vehicle location identification, detection of the vehicle's handbrake being engaged, detection of the high voltage being lowered, grabbing the vehicle-side battery, and placing the battery on the vehicle. Finally, the heavy truck completes the battery swapping process.

[0054] Figure 2 This diagram illustrates the communication connection when the train-side controller and the station control subsystem are disconnected. Figure 3 This is a schematic diagram of the monitoring process between the vehicle-side controller and the station control subsystem. The communication between the vehicle-side controller and the station control subsystem is monitored through heartbeat detection.

[0055] In a further embodiment, when the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem, specifically:

[0056] When the vehicle-end controller loses connection with the station control subsystem between the authentication process and the start of battery swapping for the heavy truck, the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem and skips the vehicle authentication process.

[0057] When the disconnection between the vehicle-end controller and the station control subsystem occurs between the start and end of the heavy truck's battery swap, the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem, skipping the vehicle authentication process and the vehicle position identification, vehicle handbrake detection, and high-voltage status detection processes.

[0058] In a further embodiment, when the disconnection between the vehicle-end controller and the station control subsystem occurs between the start and end of the battery swapping process of the heavy truck, and the current PLC control subsystem is in the process of grabbing the vehicle-end battery or placing the battery on the vehicle end, the battery swapping pause mechanism is activated. After the vehicle-end controller and the station control subsystem resume normal communication, the connection is successfully unlocked and the battery swapping is resumed.

[0059] To prevent the vehicle-side controller from losing connection with the station control system, this embodiment employs an automatic reconnection mechanism and filters out completed processes during the battery swapping procedure. If the connection is lost during the battery swapping process, the PLC control system is notified to activate a pause mechanism, thus resolving the risks associated with disassembly and installation due to battery locking.

[0060] Example 2

[0061] This embodiment continues to provide the following content based on Embodiment 1:

[0062] like Figure 4 As shown, the station control equipment in the battery swapping station includes a depth camera device, which is connected to the station control subsystem via an optical fiber.

[0063] like Figure 5 As shown, the station control subsystem controls the depth camera device to start visual photography. The depth camera device is used to acquire images during the battery swapping process and returns the acquired images to the station control subsystem via optical fiber for image recognition. The station control subsystem converts the recognized images into PLC position coordinates and outputs the coordinates to the PLC control system.

[0064] This embodiment addresses the problem of unstable communication between the station control system and the vision system caused by excessively long extension cables. It employs fiber optic cables to connect the depth camera equipment and the station control subsystem, ensuring signal transmission and resolving the issue.

[0065] Example 3

[0066] This embodiment continues to provide the following content based on Embodiment 1:

[0067] The station control equipment within the battery swapping station includes the battery swapping station charger, such as... Figure 6 As shown, the battery swapping station charger is communicatively connected to the station control subsystem. The battery swapping station charger reports the battery compartment battery code to the station control subsystem, replacing the empty battery code uploaded by the vehicle-side controller.

[0068] In a further embodiment, the battery swapping station charger reports the battery compartment battery code to the station control subsystem, such as... Figure 7 As shown, specifically:

[0069] The battery swapping station charger reports the battery compartment battery code to the station control subsystem;

[0070] The station control subsystem requests a vehicle status query from the vehicle controller.

[0071] When the vehicle-end controller receives the vehicle-end status query, if it is powered on after the battery swap is completed, it returns the battery code to the station control subsystem; if it is powered off after the battery swap is completed, the vehicle-end controller disconnects from the station control subsystem, and the station control subsystem receives an empty battery code.

[0072] Replace the empty battery code with the battery code of the battery compartment.

[0073] This embodiment addresses the issue that during the battery swapping process, the battery code cannot be obtained after installation because it is not connected to a high voltage. By communicating with the charger at the battery swapping station through the vehicle-side controller, the battery code can be obtained, thus resolving this problem.

[0074] Example 4

[0075] This embodiment continues to provide the following content based on Embodiment 1:

[0076] like Figure 8 As shown, the PLC control subsystem can also control the station control equipment within the battery swapping station to terminate the battery swapping process if there is a malfunction in the vehicle during the battery swapping process.

[0077] In a further embodiment, if a vehicle malfunctions during the battery swapping process, the PLC control subsystem controls the station control equipment within the battery swapping station to terminate the battery swapping process, such as... Figure 9 As shown, specifically:

[0078] The station control subsystem requests a vehicle status query from the vehicle controller.

[0079] When the vehicle-side controller receives the vehicle-side status query, if it is in the battery handling stage of the battery swapping process, it returns the status of whether the vehicle's handbrake is released and whether the high voltage is connected to the station control subsystem. Based on the returned status, if the vehicle is in the released handbrake or high voltage connected state, the station control subsystem notifies the PLC control subsystem to terminate the battery swapping operation. The PLC control subsystem then controls the station control equipment within the battery swapping station to terminate the battery swapping process. If the vehicle is not in the released handbrake or high voltage connected state, the battery swapping operation continues.

[0080] This embodiment aims to prevent risks such as vehicle slippage and electrical circuit failure caused by accidental operations during battery swapping, such as releasing the handbrake or applying high voltage. To ensure battery swapping safety, the vehicle status is monitored in real-time throughout the entire process. If any misoperation occurs, the entire battery swapping process is terminated, and the PLC control system is notified to stop the system immediately. This solves the problem.

[0081] The same or similar labels correspond to the same or similar parts;

[0082] The terms used to describe positional relationships in the accompanying drawings are for illustrative purposes only and should not be construed as limiting this patent.

[0083] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. An intelligent station control system for a heavy-duty truck battery swapping station, used to realize battery swapping for heavy-duty trucks, characterized in that, This includes the station control equipment within the battery swapping station, the station control subsystem, the PLC control subsystem, and the vehicle-end controller, among which: The station control equipment within the battery swapping station is communicatively connected to the station control subsystem, and the station control equipment within the battery swapping station is connected to the PLC control subsystem. The station control equipment within the battery swapping station is controlled by the PLC control subsystem. The vehicle-end controller is communicatively connected to the station control subsystem, and the PLC control subsystem is communicatively connected to the station control subsystem. When the vehicle-end controller and the station control subsystem lose connection during the heavy truck battery swapping process, the communication between the vehicle-end controller and the station control subsystem is automatically reconnected through the PLC control subsystem. The station control equipment within the battery swapping station includes a battery swapping station charger, which is communicatively connected to the station control subsystem. The station control subsystem requests a vehicle status query from the vehicle-end controller. When the vehicle-end controller receives the vehicle status query, if the battery swapping is completed and the vehicle is powered on, it returns a battery code to the station control subsystem. If the battery swapping is completed and the vehicle is powered off, the vehicle-end controller disconnects from the station control subsystem, and the station control subsystem receives an empty battery code. The empty battery code is then replaced with the battery code in the battery compartment.

2. The intelligent station control system for heavy-duty truck battery swapping stations according to claim 1, characterized in that, The heavy-duty truck battery swapping process includes the following steps: The vehicle-side controller initiates vehicle authentication to the station control subsystem. After the vehicle authentication is successful, it checks the vehicle status of the handbrake being engaged and the high voltage being lowered. Once the battery swapping conditions are met, the heavy truck begins battery swapping. The heavy truck battery swapping process includes vehicle location identification, detection of the vehicle's handbrake being engaged, detection of the high voltage being lowered, grabbing the vehicle-side battery, and placing the battery on the vehicle. Finally, the heavy truck completes the battery swapping process.

3. The intelligent station control system for heavy-duty truck battery swapping stations according to claim 2, characterized in that, The communication between the vehicle-side controller and the station control subsystem is monitored by heartbeat detection.

4. The intelligent station control system for heavy-duty truck battery swapping stations according to claim 3, characterized in that, When the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem, the specific steps are as follows: When the vehicle-end controller loses connection with the station control subsystem between the authentication process and the start of battery swapping for the heavy truck, the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem and skips the vehicle authentication process. When the disconnection between the vehicle-end controller and the station control subsystem occurs between the start and end of the heavy truck's battery swap, the PLC control subsystem automatically reconnects the communication between the vehicle-end controller and the station control subsystem, skipping the vehicle authentication process and the vehicle position identification, vehicle handbrake detection, and high-voltage status detection processes.

5. The intelligent station control system for a heavy-duty truck battery swapping station according to claim 4, characterized in that, When the disconnection between the vehicle-end controller and the station control subsystem occurs between the start and end of the battery swapping process for the heavy truck, and the current PLC control subsystem is in the process of grabbing or placing the battery on the vehicle end, the battery swapping pause mechanism is activated. After the vehicle-end controller and the station control subsystem resume normal communication, the connection is successfully unlocked and the battery swapping process is resumed.

6. The intelligent station control system for a heavy-duty truck battery swapping station according to any one of claims 1 to 5, characterized in that, The station control equipment within the battery swapping station includes a depth camera device, which is connected to the station control subsystem via an optical fiber.

7. The intelligent station control system for a heavy-duty truck battery swapping station according to any one of claims 1 to 5, characterized in that, The PLC control subsystem can also control the station control equipment within the battery swapping station to terminate the battery swapping process if there is a malfunction in the vehicle during the battery swapping process.

8. The intelligent station control system for a heavy-duty truck battery swapping station according to claim 7, characterized in that, When a vehicle malfunctions during the battery swapping process, the PLC control subsystem controls the station control equipment within the battery swapping station to terminate the battery swapping process. Specifically: The station control subsystem requests a vehicle status query from the vehicle controller. When the vehicle-end controller receives the vehicle-end status query, if it is in the battery handling stage of the battery swapping process, it returns the current status of whether the vehicle has released the handbrake and whether it has connected to high voltage to the station control subsystem. The station control subsystem determines whether the current vehicle has released its handbrake or is connected to high voltage based on the returned status. If the current vehicle is in a state where the handbrake is released or high voltage is connected, the subsystem notifies the PLC control subsystem to terminate the battery swapping operation. The PLC control subsystem then controls the station control equipment within the battery swapping station to terminate the battery swapping process. If the current vehicle is not in a state where the handbrake is released or high voltage is connected, the battery swapping operation continues.

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