Electric vehicle battery replacement system, unlocking and locking mechanism, and battery replacement method

Abstract

The present invention relates to a locking and unlocking mechanism for an electric vehicle battery replacement system. The locking and unlocking mechanism is arranged on a battery tray, and the battery tray is installed on each layer of a battery rack, including a first-layer plate and a second-layer rack, and the first-layer plate is installed above the second-layer rack. The locking and unlocking mechanism includes a Y-direction lock head and an X-Y direction lock head passing through the first-layer plate. On the back of the first-layer plate, there are an electric cylinder III, a guide rail III, an electric cylinder IV, and a guide rail IV. The X-Y direction lock head is pushed by the electric cylinder IV to slide along the guide rail IV; it also includes an electric cylinder VIII, a guide rail VIII, and a Y-direction push plate, and the Y-direction lock head is pushed by the electric cylinder VIII to slide along the guide rail VIII. The present invention solves the technical problems in the prior art that the locking and unlocking mechanism cannot adapt to batteries of different sizes and lacks the function of precise multi-directional control.

Description

Technical Field

[0001] This application belongs to the technical field of electric vehicle battery replacement, and particularly relates to an electric vehicle battery replacement system, a locking and unlocking mechanism, and a battery replacement method. Background Art

[0002] With the popularization of electric vehicles, the application of electric vehicle battery replacement systems is becoming increasingly widespread. Currently, there are many types of batteries used in electric vehicles on the market, and the sizes and specifications of the batteries vary, bringing many challenges to the locking and unlocking operations during the battery replacement process. Existing locking and unlocking mechanisms usually can only be applied to batteries of specific sizes, unable to take into account the installation and disassembly requirements of batteries of different sizes, resulting in low replacement efficiency, poor equipment versatility, and difficulty in meeting diverse market demands.

[0003] In the existing system, it is impossible to achieve precise control of the locking and unlocking mechanism in multiple directions. Especially when performing locking and unlocking operations on large-sized batteries, the common one-way movement mechanism is difficult to ensure that the locking and unlocking lock head can accurately reach the specified position, further exacerbating the inconvenience and complexity of the replacement operation. Therefore, there is an urgent need in the existing technology for a locking and unlocking mechanism that can adapt to batteries of different sizes and has the function of precise control in multiple directions to improve the versatility, stability, and operation efficiency of the battery replacement system. Summary of the Invention

[0004] Aiming at the deficiencies in the related art, the present invention provides an electric vehicle battery replacement system and a locking and unlocking mechanism, which solve the technical problems that the locking and unlocking mechanism in the existing technology is difficult to adapt to batteries of different sizes and cannot perform precise control in multiple directions.

[0005] In a possible implementation manner, a locking and unlocking mechanism for an electric vehicle battery replacement system is provided. The locking and unlocking mechanism is arranged on a battery tray, and the battery tray is arranged on each layer of a battery rack. The battery tray includes a first-layer plate and a second-layer frame, and the first-layer plate is installed above the second-layer frame.

[0006] In a possible implementation manner, the locking and unlocking mechanism includes a Y-direction lock head and an X-Y direction lock head passing through the first-layer plate. An electric cylinder III, a guide rail III, an electric cylinder IV, and a guide rail IV are arranged on the back of the first-layer plate. The output shaft of the electric cylinder IV is connected to the X-Y direction lock head, and the X-Y direction lock head is connected to the guide rail IV and can slide along the guide rail IV under the push of the electric cylinder IV. An electric cylinder VIII, a guide rail VIII, and a Y-direction push plate are also arranged on the back of the first-layer plate. The Y-direction lock head is connected to the guide rail VIII through the Y-direction push plate, and the output shaft of the electric cylinder VIII is connected to the Y-direction push plate and can push the Y-direction push plate and the connected Y-direction lock head to slide along the guide rail VIII.

[0007] In a possible implementation, the electric vehicle battery replacement system includes the above unlocking and locking mechanism, and also includes a battery rack, which is a multi-layer structure. A water and electricity connector margin mechanism corresponding to the battery charging port is installed between or on the layers of the battery rack, and the water and electricity connector margin mechanism is installed on the battery rack column.

[0008] In a possible implementation, the water and electricity connector margin mechanism includes a guide rail V installed on the battery rack column, and the guide rail V slides up and down along the battery rack column. A guide rail VI is connected to the guide rail V and is horizontally arranged. The water and electricity connector is installed on the guide rail VI and can slide horizontally along the guide rail VI.

[0009] In a possible implementation, a slider III is installed on the guide rail V, the guide rail VI is installed on the slider III through a water and electricity connector up and down sliding seat, the guide rail VI is horizontally arranged, and the water and electricity connector is installed on the guide rail VI through a slider IV. A driving mechanism drives the water and electricity connector up and down sliding seat or the slider III to slide up and down along the guide rail V. The slider III is connected to a horizontally arranged cam positioning member, and the other end of the cam positioning member is placed in the displacement groove of the water and electricity connector displacement column through a pin shaft. The displacement groove includes two connected grooves, and the distances between the two grooves and the guide rail V are different, and the different distances respectively correspond to two battery charging ports of different sizes.

[0010] In a possible implementation, the electric vehicle battery replacement system also includes a plurality of battery positioning devices. Each layer of the battery rack is provided with a battery positioning device and a battery cushion block. The battery positioning device includes a large battery positioning shaft and a small battery positioning shaft, which are respectively adapted to large batteries and small batteries of different sizes or specifications.

[0011] In a possible implementation, the battery cushion block is installed on the battery rack, corresponding to the battery positioning device, and is used to support the battery.

[0012] In a possible implementation, the water and electricity connector margin mechanism also includes a proximity switch I and an induction sheet I. The proximity switch I is installed on the column of the battery rack, and the induction sheet I is installed on the water and electricity connector up and down sliding seat. The induction sheet I slides up and down along the guide rail V with the water and electricity connector up and down sliding seat. When the induction sheet I contacts the proximity switch I, the proximity switch I is triggered and sends a signal to the control system.

[0013] In a possible implementation, the water and electricity connector is correspondingly arranged with the charging port of the large battery or the small battery.

[0014] In a possible implementation, the unlocking and locking mechanism also includes a Z-direction lock head passing through a layer board. The Z-direction lock head is installed on an I-shaped Z-direction lifting board on the back of the layer board. An electric cylinder V is installed on the back of the layer board through an electric cylinder mounting seat, and the output shaft of the electric cylinder V is connected to the Z-direction lifting board, driving the Z-direction lifting board and the Z-direction lock head thereon to move up and down in a direction perpendicular to the plane of the layer board.

[0015] In a possible implementation, the electric vehicle battery replacement system further includes a palletizer corresponding to the battery rack. The palletizer includes a palletizer lifting frame, an adjusting frame, a fork, an electric cylinder I, a guide rail VII, and a fork telescopic motor reducer assembly installed on the lifting frame. Two forks are installed on the adjusting frame, and the adjusting frame is installed on the palletizer lifting frame through the guide rail VII. The fork telescopic motor reducer assembly is installed on the adjusting frame and is used to drive the fork to extend and retract. The push rod of the electric cylinder I is connected to the adjusting frame and drives the adjusting frame to move horizontally to adjust the positions of the two forks. The electric cylinder I is installed on the palletizer lifting frame through an electric cylinder mounting seat, and its push rod is connected to the adjusting frame through a push rod connecting block.

[0016] In a possible implementation, the palletizer further includes a palletizer support. The palletizer lifting frame is installed on the palletizer support through a lifting mechanism, and the lifting mechanism drives the lifting frame to move up and down along the support. It also includes a fall arrester, which is installed on the palletizer lifting frame through a mounting seat. The fall arrest guide rail is installed on the column of the palletizer support and extends along the movement direction of the lifting frame. There is a gap in the middle of the fall arrester, and the fall arrest guide rail is placed in the gap. When the lifting frame reaches the set position, the gap clamps the fall arrest guide rail to prevent the lifting frame from falling.

[0017] In a possible implementation, the battery replacement method uses the above-mentioned electric vehicle battery replacement system and includes the following steps:

[0018] Control the feed battery to move to the interlayer or on the layer of the battery rack, and according to the model of the feed battery, control the large battery positioning shaft or the small battery positioning shaft to position the feed battery; control the Z-direction lock head, the Y-direction lock head, and the X-Y direction lock head to lock the feed battery; according to the model of the feed battery, control the drive mechanism to drive the slider III or the upper and lower slides of the water and electricity connector to remain stationary or move downward, so that the water and electricity connector is docked with the charging port of the feed battery.

[0019] Based on the above technical solutions, the locking and unlocking mechanism of the electric vehicle battery replacement system of the present invention realizes the stable locking and unlocking of the battery tray in multiple directions by setting the Y-direction and X-Y direction lock heads. Through the precise control of each lock head driven by the electric cylinder, the locking and unlocking operations of the battery can be automatically completed during the battery replacement process, greatly improving the efficiency and safety of battery replacement. This system is especially suitable for battery racks with a multi-layer structure, makes more effective use of space, and can adapt to batteries of different sizes, further improving the automation level and applicability of electric vehicle battery replacement. Description of the Drawings

[0020] The drawings described herein are used to provide a further understanding of the present invention and form a part of this application. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0021] Figure 1Schematic structural diagram of the battery rack assembly of the present invention;

[0022] Figure 1a Schematic structural diagram of the positioning device of the battery rack assembly of the present invention;

[0023] Figure 2 Schematic structural diagram of the palletizer of the present invention;

[0024] Figure 3 Schematic structural diagram of the adjustment frame of the palletizer of the present invention;

[0025] Figure 4 Schematic diagram of the installation position of the anti - falling mechanism of the lifting mechanism of the palletizer of the present invention;

[0026] Figure 5 Schematic structural diagram of the anti - falling device of the lifting mechanism of the palletizer of the present invention;

[0027] Figure 6 Schematic structural diagram of the side scissor component of the unlocking and locking mechanism;

[0028] Figure 7 Schematic structural diagram of the drag chain of the unlocking and locking mechanism;

[0029] Figure 8 Schematic diagram of the movement direction of the unlocking and locking head in the top - view of the unlocking and locking mechanism of the present invention;

[0030] Figure 9 Back - side layout of the top - layer plate of the unlocking and locking mechanism of the present invention;

[0031] Figure 9a Schematic structural diagram of the overall unlocking and locking mechanism of the present invention;

[0032] Figure 10 Schematic diagram of the double - layer electric cylinder layout on the back - side of the top - layer plate of the unlocking and locking mechanism of the present invention;

[0033] Figure 11 Schematic diagram of the installation of the middle four locking heads of the unlocking and locking mechanism of the present invention;

[0034] Figure 11a Partial enlarged view of the unlocking and locking mechanism of the present invention;

[0035] Figure 11b Schematic structural diagram of the second - layer rack of the present invention;

[0036] Figure 12 Schematic diagram of the water - and - electricity connection margin mechanism of the present invention;

[0037] Figure 12a Schematic diagram of the water - and - electricity connection margin mechanism of the present invention;

[0038] Figure 12b Partial structural diagram of the proximity switch of the water - and - electricity connection margin mechanism of the present invention.

[0039] In the figure:

[0040] 1. Battery rack; 11. Large battery; 12. Small battery; 21. Large battery positioning shaft; 22. Small battery positioning shaft; 3. Battery cushion block; 4. Palletizer; 41. Palletizer lifting frame; 42. Adjusting frame; 43. Fork; 441. Electric cylinder I; 442. Electric cylinder mounting seat; 443. Push rod connecting block; 45. Guide rail VII; 46. Palletizer telescopic motor reducer assembly; 47. Palletizer bracket; 49. Fall arrester; 491. Fall arrester mounting seat; 492. Fall arrester guide rail; 6. Locking and unlocking mechanism; 61. First layer board; 62. Second layer frame; 63. Z-direction lock head; 64. Y-direction lock head; 65. X-Y direction lock head; 66. Z-direction lifting plate; 67. Electric cylinder V; 671. Electric cylinder mounting seat; 68. Guide shaft; 69. Electric cylinder III; 610. Guide rail III; 611. Electric cylinder IV; 612. Guide rail IV; 613. Electric cylinder VIII; 614. Guide rail VIII; 615. Y-direction push plate; 616. Electromagnet; 617. Side shear fork; 618. Fixed seat; 619. Sliding seat; 620. Guide rail VII; 621. Pin shaft II; 622. Drag chain; 623. Duct; 7. Water and electricity joint margin mechanism; 71. Guide rail V; 72. Slide block III; 73. Guide rail VI; 74. Water and electricity joint up and down sliding seat; 75. Water and electricity joint; 76. Slide block IV; 77. Driving mechanism; 78. Cam positioning part; 79. Pin shaft I; 710. Water and electricity joint displacement column; 711. Displacement groove; 712. Proximity switch I; 713. Inductive sheet I. Detailed implementation manners

[0041] Next, the technical solutions in the embodiments will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0042] In the description of the present application, it should be understood that the terms "center", "transverse", "longitudinal", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation of the present application.

[0043] The terms "first", "second", and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first", "second", and "third" may explicitly or implicitly include one or more of such features.

[0044] In the description of this application, it should be noted that unless otherwise clearly specified and defined, the terms "installed", "connected", and "coupled" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0045] To solve the technical problems in the prior art that the unlocking and locking mechanism is difficult to adapt to batteries of different sizes and cannot perform precise control in multiple directions. This application provides an electric vehicle battery replacement system, an unlocking and locking mechanism, and a battery replacement method.

[0046] See Figure 1 - Figure 1a , in a possible implementation, the battery rack assembly of the electric vehicle battery replacement system includes a battery rack 1 and a plurality of battery positioning devices. The battery rack 1 is a multi-layer structure, and each layer is provided with a battery positioning device and a battery cushion block 3. The battery positioning device includes a large battery positioning shaft 21 and a small battery positioning shaft 22, and the large battery positioning shaft 21 and the small battery positioning shaft 22 are respectively adapted to batteries 11 and 12 of different sizes or specifications and are installed on the battery rack 1. The battery cushion block 3 is installed on the battery rack 1 and is arranged corresponding to the battery positioning device for supporting the large battery 11 and the small battery 12.

[0047] The electric vehicle battery replacement system includes a battery rack 1 and a plurality of battery positioning devices. The battery rack 1 adopts a multi-layer structure, and each layer is provided with a battery positioning device and a battery cushion block 3. The battery positioning device consists of a large battery positioning shaft 21 and a small battery positioning shaft 22, which are respectively applicable to batteries 11 and 12 of different sizes or specifications. The battery positioning shafts 21 and 22 are installed on the battery rack 1 to enable the batteries to be stably installed and positioned. The battery cushion block 3 is installed on the battery rack 1 and is arranged corresponding to the battery positioning device for supporting the batteries to ensure the stability of the batteries during use.

[0048] In the above-described embodiment, the multi-layer structure design of the battery rack 1 enables the system to accommodate multiple batteries, and different positioning devices are adapted to different sizes of batteries. The large battery positioning shaft 21 and the small battery positioning shaft 22 are respectively adapted to the batteries according to their sizes, ensuring the stable fixation of the batteries on the battery rack 1. The cooperation between the battery cushion block 3 and the battery positioning device can effectively support the battery, prevent the battery from shaking or shifting during use, and ensure the safety and stability of the battery during the operation of the electric vehicle.

[0049] The system design can adapt to various specifications of batteries, improving the convenience and adaptability of battery replacement for electric vehicles. In addition, through the supporting effect of the battery cushion block 3, the stability of battery installation is further enhanced, the damage caused by vibration or impact to the battery is reduced, and the service life of the battery is extended.

[0050] See Figure 2 and Figure 3 In a possible embodiment, a palletizer 4 is further included. The palletizer 4 is arranged corresponding to the battery rack 1 and includes a palletizer lifting frame 41, an adjusting frame 42 mounted on the palletizer lifting frame 41, a fork 43, an electric cylinder I 441, a guide rail VII 45, and a fork telescopic motor reducer assembly 46. Two forks 43 are respectively mounted on two adjusting frames 42, and the two adjusting frames 42 are respectively mounted on the palletizer lifting frame 41 through the guide rail VII 45. The fork telescopic motor reducer assembly 46 and the push rod of the electric cylinder I 441 are respectively connected to the two adjusting frames 42 through a push rod connection block 443 to drive the two adjusting frames 42 to move towards or away from each other, adjusting the distance between the two forks 43. The electric cylinder I 441 is mounted on the palletizer lifting frame 41 through an electric cylinder mounting seat 442, and the push rod is connected to the adjusting frame 42 through a push rod connection block 443.

[0051] The battery replacement system for the electric vehicle further includes a palletizer 4. The palletizer 4 is arranged corresponding to the battery rack 1 and specifically includes a palletizer lifting frame 41, an adjusting frame 42, a fork 43, an electric cylinder I 44, a guide rail VII 45, and a fork telescopic motor reducer assembly 46. Two forks 43 are provided and mounted on the adjusting frame 42, and the adjusting frame 42 is mounted on the palletizer lifting frame 41 through the guide rail VII 45. The fork telescopic motor reducer assembly 46 is mounted on the adjusting frame 42 for driving the fork 43 to extend and retract. The electric cylinder I 44 is connected to the adjusting frame 42 through a push rod connection block 443, thereby driving the adjusting frame 42 to move horizontally to adjust the horizontal position of the two forks 43. The electric cylinder I 44 is mounted on the palletizer lifting frame 41 through an electric cylinder mounting seat 442, and the push rod is connected to the adjusting frame 42 through a push rod connection block 443 to realize the position adjustment of the fork 43.

[0052] In the above embodiment, the palletizer 4 can flexibly move between different heights of the battery rack 1 through its lifting frame 41. The electric cylinder I 441 pushes the movement of the adjustment frame 42 through the push rod connecting block 443 to adjust the horizontal position of the fork. The fork telescopic motor reducer assembly 46 is installed on the adjustment frame 42 and is used to drive the fork 43 to telescope, so as to adjust the distance that the fork extends; the structural settings of the electric cylinder I 441, the fork telescopic motor reducer assembly 46, the adjustment frame 42 and the fork 43 enable the system to accurately adjust the position of the fork and the distance that the fork extends, so as to adapt to batteries or battery packs of different sizes.

[0053] The flexibility and precision of the palletizer system significantly improve the efficiency of battery replacement. By adjusting the distance between the forks, it can quickly adapt to batteries of different sizes, reduce the need for manual intervention, and reduce the risk of misoperation when installing or removing the battery.

[0054] In a possible embodiment, the palletizer 4 further includes a palletizer bracket 47. The palletizer lifting frame 41 is installed on the palletizer bracket 47 through a palletizer lifting mechanism, and the palletizer lifting mechanism drives the palletizer lifting frame 41 to move up and down along the palletizer bracket 47. Refer to Figure 4 and Figure 5 , the anti-fall device 49 is installed on the palletizer lifting frame 41 through the anti-fall device mounting seat 491, and the anti-fall guide rail 492 is installed on the column of the palletizer bracket 47, which is consistent with the movement direction of the palletizer lifting frame 41 and extends along the column. When the palletizer lifting frame 41 reaches the set position below, the gap in the anti-fall device 49 will clamp the anti-fall guide rail 492 to prevent the palletizer lifting frame 41 from falling.

[0055] In the above embodiment, the palletizer lifting frame 41 can be freely adjusted to different heights through the palletizer lifting mechanism, ensuring the convenience and precision of battery replacement. The design of the anti-fall device 49 automatically locks when the lifting frame 41 reaches the set position, avoiding accidental falling, so as to ensure the safety of the operation.

[0056] The system effectively prevents the lifting frame from accidentally falling through the anti-fall device, ensuring the safety of the operator. At the same time, the precise control of the lifting mechanism enables the palletizer 4 to efficiently replace the battery in various complex scenarios.

[0057] Refer to Figure 1 and Figure 6 - Figure 9a, the battery replacement system of the electric vehicle further includes a locking and unlocking mechanism 6, which is arranged on the battery tray 56. The battery tray 56 includes a first layer plate 61 and a second layer frame 62, and the first layer plate 61 is installed above the second layer frame 62; the locking and unlocking mechanism 6 includes a Z-direction lock head 63, a Y-direction lock head 64, and an X-Y direction lock head 65 passing through the first layer plate 61; among them, the Z-direction lock head 63 is installed on the second layer frame 62 on the back of the first layer plate 61 through an I-shaped Z-direction lifting plate 66, and an electric cylinder V 67 is installed on the back of the first layer plate 61 or the second layer frame 62. The output shaft of the electric cylinder V 67 is connected to the Z-direction lifting plate 66, driving the Z-direction lifting plate 66 and the Z-direction lock head 63 thereon to move up and down in a direction perpendicular to the plane of the first layer plate 61; a guiding shaft 68 is arranged on the Z-direction lifting plate 66, passing through the first layer plate 61, and the Z-direction lifting plate 66 and the Z-direction lock head 63 thereon move up and down along the guiding shaft 68; an electric cylinder III 69, a guide rail III 610, an electric cylinder IV 611, and a guide rail IV 612 are arranged on the back of the first layer plate 61. The output shaft of the electric cylinder IV 611 is connected to the X-Y direction lock head 65, and the X-Y direction lock head 65 is connected to the guide rail IV 612 and can slide along the guide rail IV 612 under the push of the electric cylinder IV 611; the output shaft of the electric cylinder III 69 is connected to the guide rail IV 612, and the guide rail IV 612 is installed on the guide rail III 610 and can slide along the guide rail III 610 under the push of the electric cylinder III 69, and the guide rail IV 612 is perpendicular to the guide rail III 610; an electric cylinder VIII 613, a guide rail VIII 614, and a Y-direction pushing plate 615 are arranged on the back of the first layer plate 61. The Y-direction lock head 64 is connected to the guide rail VIII 614 through the Y-direction pushing plate 615, and the output shaft of the electric cylinder VIII 613 is connected to the Y-direction pushing plate 615 and can push the Y-direction pushing plate 615 and the Y-direction lock head 64 connected thereto to slide along the guide rail VIII 614.

[0058] The locking and unlocking mechanism 6 realizes the automatic locking and unlocking function of the battery tray 56 through the lock heads in three directions (Z-direction, Y-direction, and X-Y direction) and their corresponding electric cylinders and guide rail systems. The Z-direction lock head 63 moves up and down along the guiding shaft 68 under the action of the electric cylinder V 67 to ensure locking or releasing the battery tray 56 in the vertical direction. The Y-direction lock head 64 and the X-Y direction lock head 65 slide on the corresponding guide rails VIII 614 and IV 612 respectively under the push of the electric cylinder VIII 613 and the electric cylinder IV 611, realizing the locking or releasing of the battery tray 56 in the Y-direction and the X-Y direction. Through this multi-directional locking and unlocking design, the battery tray 56 can be firmly fixed in three-dimensional space, ensuring the safety and stability of the battery during the replacement process.

[0059] The locking and unlocking mechanism provides a multi-directional locking method to ensure the safety and reliability of the battery during installation and replacement. The multi-directional locking design not only enhances the fixing effect of the battery but also improves the operation efficiency of the entire system.

[0060] In a possible implementation, there are four Z-direction lock heads 63, which are respectively arranged at the four end points of the I-shaped Z-direction lifting plate 66. The first-layer plate 61 and the second-layer frame 62 are adsorbed and connected by an electromagnet 616, and four electromagnets 616 are provided.

[0061] In the above implementation, the number of Z-direction lock heads 63 is four, which are respectively arranged at the four end points of the I-shaped Z-direction lifting plate 66 to ensure the locking of the battery at multiple points and improve the stability of fixation. The electromagnet 616 provides additional adsorption force, and tightly connects the first-layer plate 61 and the second-layer frame 62 together through electromagnetic adsorption, further enhancing the stability and safety of the overall structure.

[0062] This design effectively improves the fixation performance and operation safety of the system by increasing the number of Z-direction lock heads 63 and introducing electromagnetic adsorption connection. Especially in application scenarios that require higher strength and reliability, this design can provide a more stable and reliable battery fixation effect.

[0063] See Figure 6 , in a possible implementation, a set of side scissor assemblies are arranged between the first-layer plate 61 and the second-layer frame 62. This assembly includes two side scissors 617, two fixed seats 618, two sliding seats 619, and two guide rails 620. The two side scissors 617 are cross-shaped, and are respectively fixed to the first-layer plate 61 and the second-layer frame 62 through the fixed seats 618, and the other ends are connected to the guide rails 620 through the sliding seats 619, and the guide rails 620 are installed on the first-layer plate 61 and the second-layer frame 62.

[0064] The side scissor assembly provides additional support and adjustment functions for the first-layer plate 61 and the second-layer frame 62 through the X-shaped structure. During the installation and disassembly of the first-layer plate of the battery, the side scissor assembly can bear the gravity of the first-layer plate and guide its smooth movement. Through the sliding of the sliding seat 619 on the guide rail 620, the side scissor assembly can achieve flexible adjustment of the first-layer plate, ensuring stability and precise positioning during the battery replacement process.

[0065] In another implementation, the number and size of the side scissor assemblies can be adjusted according to the weight and size of the first-layer plate of the battery. The designs of the guide rails 620 and the sliding seats 619 can also be optimized as needed, and more durable or corrosion-resistant materials can be selected to adapt to applications in harsh environments.

[0066] In a possible implementation, two sets of side scissor assemblies are provided, which are respectively arranged in parallel on the opposite sides of the first-layer plate 61 and the second-layer frame 62. These two sets of side scissor assemblies can provide support and adjustment functions for the pallet at different positions of the battery pallet, so as to realize the stable movement and locking of the first-layer plate of the battery.

[0067] Two sets of side scissor components are respectively installed on the opposite sides of the battery tray. This parallel arrangement further enhances the stability and load-bearing capacity of the tray. During the battery replacement process, the side scissor components can not only support the tray but also adjust the height and position of the tray in both the vertical and horizontal directions to ensure that the battery one-layer board can be smoothly locked or unlocked.

[0068] In a possible implementation manner, the X-shaped center of the two side scissors 617 is connected by a pin shaft II 621. The rotation function of the pin shaft 621 around its center point enables the side scissors 617 to achieve flexible telescoping and adjustment, enhancing the moving ability of the tray.

[0069] The X-shaped structure of the side scissors 617 is connected by the pin shaft 621, allowing the side scissors to rotate around the pin shaft and providing stable adjustment ability in the up and down direction of the one-layer board. During the battery replacement process, when the one-layer board moves up and down, the pin shaft 621 allows the side scissor components to automatically adjust according to the height change of the one-layer board to maintain the balance and stability of the one-layer board.

[0070] See Figure 7 , in a possible implementation manner, the unlocking and locking mechanism further includes a drag chain 622. The drag chain 622 is arranged between the one-layer board 61 and the two-layer rack 62 and is used for laying the cables of the motor and the switch equipment. A duct 623 is provided inside the drag chain 622, and the cables are laid and protected through the duct 623 to ensure the safety and reliability of the cables during the movement of the one-layer board.

[0071] The drag chain 622 is connected to the one-layer board 61 and the two-layer rack 62 through its flexible design. The duct 623 is used to accommodate the cables of the motor and the switch equipment. During the movement of the battery one-layer board, the drag chain 622 expands and contracts as the one-layer board moves to ensure that the cables will not be damaged or broken due to the movement of the one-layer board. At the same time, the duct 623 provides good cable protection to prevent damage to the cables caused by the external environment.

[0072] See Figure 12 and Figure 12a , in a possible implementation manner, it further includes a water and electricity joint margin mechanism 7 corresponding to the battery charging port installed between or on the layers of the battery rack 1. The water and electricity joint margin mechanism 7 includes a guide rail V 71 installed on the column of the battery rack 1. A slider III 72 is installed on the guide rail V 71. A guide rail VI 73 is installed on the slider III 72 through a water and electricity joint up and down slide seat 74. The guide rail VI 73 is horizontally arranged. A water and electricity joint 75 is installed on the guide rail VI 73 through a slider IV 76. A driving mechanism 77 drives the water and electricity joint up and down slide seat 74 or the slider III 72 to slide up and down along the guide rail V 71.

[0073] In the above-described embodiment, the water and electricity connector margin mechanism 7 achieves precise positioning of the water and electricity connector 75 through a guide rail system installed on the column of the battery rack 1. The combined design of the slider III 72, the guide rail V 71, and the guide rail VI 73 enables the water and electricity connector 75 to slide freely in both the vertical and horizontal directions, so as to accurately dock with the charging port of the battery. The driving mechanism 77 realizes precise adjustment of the docking by controlling the movement of the upper and lower sliding seats 74 of the water and electricity connector or the slider III 72.

[0074] This design effectively improves the efficiency and reliability of battery charging by precisely controlling the position of the water and electricity connector. The multi-directional sliding function of the water and electricity connector margin mechanism ensures a smooth docking process, reduces errors, and improves the automation level of the system.

[0075] See Figure 12b , in a possible embodiment, the water and electricity connector margin mechanism 7 further includes: a proximity switch I 712 installed on the column of the battery rack 1; and an induction piece I 713 installed on the upper and lower sliding seats 74 of the water and electricity connector and sliding up and down along the guide rail V 71 with the sliding seat.

[0076] When the induction piece I 713 contacts the proximity switch I 712, the proximity switch I 712 is triggered and sends a signal to the control system to confirm that the water and electricity connector 75 has been aligned with the battery charging port.

[0077] The induction piece I 713 moves along the guide rail V 71 with the sliding seat of the water and electricity connector. When it reaches a predetermined position, the induction piece I 713 cooperates with the proximity switch I 712 to trigger the control system to stop the sliding operation. This design ensures the precise docking of the water and electricity connector 75 with the battery charging port and avoids docking errors.

[0078] In a possible embodiment, the electric vehicle battery replacement system further includes a water and electricity connector margin mechanism corresponding to the battery charging port installed between or on the battery rack layers. The margin mechanism includes a guide rail V installed on the column of the battery rack, a slider III installed on the guide rail V, a guide rail VI installed on the slider III through the upper and lower sliding seats of the water and electricity connector, the guide rail VI is horizontally arranged, and the water and electricity connector is installed on the guide rail VI through a slider IV. The driving mechanism drives the upper and lower sliding seats of the water and electricity connector or the slider III to slide up and down along the guide rail V. The slider III is connected to a horizontally arranged cam positioning member, and the other end of the cam positioning member is placed in the displacement groove of the water and electricity connector displacement column through a pin shaft. The displacement groove includes two connected grooves, and the distances between these two connected grooves and the guide rail V are different. The different distances of the two grooves respectively correspond to the charging ports of two different-sized batteries.

[0079] In the above-described embodiment, the slider III is connected to the horizontally arranged cam positioning member. Through the operation of the driving mechanism, the slider III slides up and down along the guide rail V. As the slider III moves, the cam positioning member pushes the water and electricity joint displacement column to move within the displacement slot through the pin shaft. The design of the two connected slots of the displacement slot enables the water and electricity joint to automatically adjust its position according to the different sizes of the batteries, thereby achieving precise docking with the charging ports of different-sized batteries.

[0080] This design realizes the automatic adaptability of the water and electricity joint to different-sized batteries through the two-slot structure of the displacement slot, greatly improving the versatility and compatibility of the system. Regardless of the battery size, the system can accurately dock, avoiding the cumbersome steps of manual adjustment, and enhancing the charging efficiency and safety.

[0081] In a possible embodiment, a method for charging electric vehicle batteries of different specifications is applied to the electric vehicle battery replacement system of any one of the above. The method includes the following steps:

[0082] Control the feed battery to move to the interlayer or on the layer of the battery rack, and according to the model of the feed battery, control the large battery positioning shaft or the small battery positioning shaft to position the feed battery.

[0083] Control the Z-direction lock head, Y-direction lock head, and X-Y direction lock head to lock the feed battery.

[0084] According to the model of the feed battery, control the driving mechanism to drive the slider III or the up and down slide of the water and electricity joint to keep it stationary or move downward, so that the water and electricity joint is docked with the charging port of the feed battery.

[0085] This battery replacement method is operated based on the above electric vehicle battery replacement system and includes the following steps:

[0086] Control the movement of the feed battery:

[0087] The system moves the battery to be replaced to the interlayer or a certain layer of the battery rack. The models of different batteries are identified by the control system.

[0088] Battery positioning and locking:

[0089] According to the model of the feed battery, the system controls the large battery positioning shaft 21 or the small battery positioning shaft 22 to perform adaptive positioning on the battery to ensure that the battery is accurately in place. After positioning, the Z-direction lock head 63, Y-direction lock head 64, and X-Y direction lock head 65 lock the feed battery in sequence to achieve multi-directional fixation of the battery.

[0090] Slide and dock the charging port:

[0091] According to the battery model and the position requirements of the charging port, the driving mechanism 77 drives the slider III 72 or the upper and lower sliders 74 of the water and electricity connector to move along the guide rail V 71 to an appropriate position. After the sliding is completed, the water and electricity connector 75 is accurately docked with the battery charging port.

[0092] Charging status detection and feedback:

[0093] When the water and electricity connector 75 is successfully connected to the battery charging port, the induction sheet I 713 contacts the proximity switch I 712 as the slider 74 slides, triggering the control system to send a signal to confirm the connection status. At this time, the system can start charging or replacing the depleted battery according to the feedback information.

[0094] This method realizes the accurate positioning and charging docking of different specifications of batteries through automatic control, effectively reducing the errors and time of manual operation, improving the charging efficiency and the intelligence level of the system. At the same time, the multi-directional locking design ensures the safety of the charging process and reduces the risk of charging failures caused by battery vibration or unstable connections.

[0095] Some other embodiments of the present invention are as follows:

[0096] I. Battery rack

[0097] 1. The battery rack is provided with positioning devices for two types of batteries. The palletizer adjusts the positions of different batteries, so that the batteries are placed on two positioning shafts. The positioning shafts are installed on the battery rack by screws, enabling the battery rack to be compatible with both large and small batteries and charging the batteries. See Figure 1 .

[0098] II. Palletizer

[0099] 1. The fork of the palletizer is equipped with a fork displacement mechanism. During the process of lifting the fork, the fork on the adjustment frame is pushed by an electric cylinder to achieve displacement adjustment of the fork in the directions perpendicular to the extending direction and the vertical direction. The entire extending mechanism of the two forks is arranged on the adjustment frame, and the adjustment frame is pushed by an electric cylinder to achieve short-distance movement while ensuring that the fork spacing remains unchanged. See Figure 2 and Figure 3 . By adjusting the displacement of the adjustment frame, the large and small batteries are placed so that their charging interfaces are in the same position, distinguishing the edge distance mechanism of the water and electricity connector in item 5.1. This scheme is to move the battery to adapt to the fixed position of the water and electricity connector.

[0100] 2. The lifting mechanism of the palletizer is newly equipped with a fall arrester for anti-fall. By installing an anti-fall guide rail on the column of the palletizer and placing the anti-fall guide rail in the middle gap of the fall arrester, if the synchronous belt breaks or the lifting mechanism fails and falls due to other reasons, the fall arrester will clamp the anti-fall guide rail to hold the lifting frame and prevent it from falling, improving the operation safety and emergency handling ability of the palletizer. See Figure 4 Figure 5 .

[0101] III. Locking and unlocking

[0102] 1. The locking and unlocking mechanism can adapt to two types of batteries with different sizes. By driving the locking and unlocking head to move through an electric cylinder, locking and unlocking operations can be performed on the two types of batteries with different sizes. When disassembling and installing a small battery, the locking and unlocking joint moves inward under the push of the electric cylinder. When disassembling and installing a large battery, the locking and unlocking joint moves to the outer edge as shown in Figure 8 Figure. On the back side of the first-layer plate of the locking and unlocking mechanism, there is an electric cylinder-driven guide rail slider mechanism. The locking and unlocking head is connected through a push plate, which is separately suitable for loading and unloading two types of batteries with different sizes. At the same time, four electromagnets are arranged to ensure that the top layer plate of the locking and unlocking mechanism will not shift during operation as shown in Figure 9 Figure. At the same time, to achieve the disassembly and installation of a large battery, the two corner locks "L" move in the (X-Y direction). Two layers of electric cylinders are arranged to push and control their movement in two directions and reach the specified position as shown in Figure 10 Figure.

[0103] When the locking and unlocking head works, the head moves to a position suitable for the corresponding battery and is lifted under the drive of the electric cylinder. The four middle locks are simultaneously lifted under the action of the electric cylinder connected to the Z-direction lifting plate, saving the internal space of the locking and unlocking mechanism. Subsequently, the 12 locks perform the locking and unlocking operations.

[0104] 2. The four middle locks of the locking and unlocking mechanism are connected through an "I"-shaped Z-direction lifting plate. The Z-direction lifting plate determines the Z-direction movement direction through two guide shafts and is connected to the top layer plate through an electric cylinder and an electric cylinder mounting seat. The lifting of the four locking and unlocking heads is realized by using the electric cylinder as shown in Figure 11 Figure.

[0105] IV. Margin mechanism for water and electricity connectors

[0106] 1. The water and electricity connector is provided with a margin mechanism as shown in Figure 12 and Figure 12a Figure. When charging, by controlling the falling distance of the water and electricity connector, the extending distance of the water and electricity connector is controlled so that it can be suitable for charging two types of batteries placed on the battery rack. This solution is applicable to the case without a palletizing machine moving adjustment frame, that is, in the case of II.1, and the position of the water and electricity connector is moved to adapt to two types of batteries with different sizes.

[0107] As another implementation method, the battery swapping process and mechanism of the battery swapping station are described as follows;

[0108] The battery swapping system of the present invention is used to reduce the occupied volume of the battery swapping station while not reducing the battery swapping time. The existing technologies are as follows:

[0109] 1. A buffer position is set in the battery swapping station for placing the removed battery. After the discharged battery removed from the vehicle is placed in the buffer position, the fully charged battery moves from the connection position to the RGV, and then the fully charged battery is installed on the vehicle. Preferably, the battery in the buffer position moves to the battery compartment.

[0110] Disadvantages of the prior art 1: The buffer positions occupy more usable area, and the cabinet of the battery swapping station also needs to be larger.

[0111] 2. Cancel the connection position. After the removed batteries are sent into the battery compartment, then move a new battery onto the RGV.

[0112] Disadvantages of the prior art 2: The battery swapping time is too long. After the vehicle battery is disassembled, it needs to be sent to the battery compartment first, and then another battery is moved, which increases more time and has a bad impact on the customer experience.

[0113] The present invention describes a battery swapping process and mechanism. The buffer positions are cancelled, reducing the occupied area and the size of the cabinet of the battery swapping station. The conveying mechanism from the connection position to the RGV adopts a double-layer design. Before battery swapping, a fully charged battery is prepared on the lower layer first. The discharged battery removed is moved from the RGV to the upper layer, the discharged battery is transported from the upper layer to the connection position, and the fully charged battery is transported from the lower layer to the RGV.

[0114] A1 and A2, B1 and B2 are two groups of mechanisms for lifting the batteries. They are in upper and lower layers and reciprocate left and right on the slide rails through belts.

[0115] A1 and A2 are responsible for transporting the removed old batteries, and B1 and B2 are responsible for transporting the fully charged new batteries to be installed.

[0116] First, place the fully charged new battery on B1B2. A1 and A2 move to the discharged battery removed and lift the battery up. Then A1A2 move to the right, and simultaneously B1B2 move to the left; the two groups of lifting mechanisms move synchronously, reducing the handling time. After the battery swapping is completed, move the battery on A1A2 to the battery rack. A1A2 move to the left, and B1B2 move to the right to return to the origin.

[0117] 1. This solution adopts a double-layer conveying mechanism design, reducing the buffer positions. At the same time, it does not reduce the battery swapping speed, reducing the cost of the battery swapping station while retaining the battery swapping experience; adopts a double-layer conveying mechanism, and the conveying mechanism is in the form of a battery swapping cart instead of a double-layer conveyor belt; adopts the method of lifting and moving to transport the batteries.

[0118] Finally, it should be noted that: the various embodiments in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments. For the same and similar parts between the various embodiments, reference can be made to each other.

[0119] The above embodiments are only used to illustrate the technical solutions of the present application rather than to limit them; although the present application has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that: it is still possible to modify the specific implementation manners of the present application or perform equivalent replacements on some technical features; without departing from the spirit of the technical solutions of the present application, they should all be covered within the scope of the technical solutions claimed in the present application.

Claims

1. An electric vehicle battery replacement system, characterized in that: include: A battery rack (1) and an unlocking mechanism for an electric vehicle battery replacement system, The locking and unlocking mechanism (6) is arranged on a battery support plate, and the battery support plate is arranged on each layer of the battery rack (1); the battery support plate comprises a first layer plate (61) and a second layer rack (62), and the first layer plate (61) is installed above the second layer rack (62); The locking and unlocking mechanism (6) comprises a Y-direction locking head (64) and an XY-direction locking head (65) passing through a layer of plate (61); An electric cylinder III (69), a guide rail III (610), an electric cylinder IV (611) and a guide rail IV (612) are arranged on the back of a layer plate (61); the output shaft of the electric cylinder IV (611) is connected to an XY-direction lock head (65); the XY-direction lock head (65) is connected to the guide rail IV (612) and can slide along the guide rail IV (612) under the push of the electric cylinder IV (611); An electric cylinder VIII (613), a guide rail VIII (614) and a Y-direction push plate (615) are arranged on the back of a layer plate (61); the Y-direction lock head (64) is connected to the guide rail VIII (614) via the Y-direction push plate (615); an output shaft of the electric cylinder VIII (613) is connected to the Y-direction push plate (615) and can push the Y-direction push plate (615) and the Y-direction lock head (64) connected thereto to slide along the guide rail VIII (614); The battery rack (1) is a multi-layer structure; a water-electricity joint margin mechanism (7) corresponding to the battery charging port is installed between or on the layers of the battery rack (1), and the water-electricity joint margin mechanism (7) is installed on the column of the battery rack (1); the water-electricity joint margin mechanism (7) comprises: a guide rail V (71) installed on the column of the battery rack, and the guide rail V (71) slides up and down along the column of the battery rack; a guide rail VI (73) is connected to the guide rail V (71), and the guide rail VI (73) is arranged horizontally, and the water-electricity joint (75) is installed on the guide rail VI (73) and can slide horizontally along the guide rail VI (73); The slider III (72) is mounted on the guide rail V (71), and the guide rail VI (73) is mounted on the slider III (72) through the upper and lower slide seats (74) of the water and electricity connector. The guide rail VI (73) is arranged horizontally, and the water and electricity connector (75) is mounted on the guide rail VI (73) through the slider IV (76). The driving mechanism (77) drives the upper and lower slide seats (74) of the water and electricity connector or the slider III (72) to slide up and down along the guide rail V (71). The slider III (72) is connected to a horizontally arranged cam positioning member (78), and the other end of the cam positioning member (78) is placed in a displacement groove (711) of a water and electricity connector displacement column (710) through a pin shaft (79). The displacement groove (711) includes two sections of connected grooves, and the distances between the two sections of connected grooves and the guide rail V (71) are different. The different distances at the two ends correspond to charging ports of two batteries of different sizes.

2. The electric vehicle battery replacement system according to claim 1, characterized in that: It also includes a plurality of battery positioning devices, with each layer of the battery rack (1) being provided with a battery positioning device and a battery cushion block (3); The battery positioning device comprises a large battery positioning shaft (21) and a small battery positioning shaft (22). The large battery positioning shaft (21) and the small battery positioning shaft (22) are mounted on the battery rack (1) and are respectively adapted to large batteries (11) and small batteries (12) of different sizes or specifications.

3. The electric vehicle battery replacement system according to claim 2, characterized in that: Also includes: The battery pad (3) is mounted on the battery rack (1) and is arranged corresponding to the battery positioning device, and is used to support the battery.

4. The electric vehicle battery replacement system according to claim 3, characterized in that: The water and electricity joint margin mechanism (7) also includes: A proximity switch I (712) is mounted on a column of the battery rack (1); The induction sheet I (713) is mounted on the upper and lower sliding seats (74) of the water and electricity joint; When the induction sheet I (713) slides up and down along the guide rail V (76) along with the water and electricity joint upper and lower slide seat (74) until it contacts the proximity switch I (712), the proximity switch I (712) is triggered to send a signal to the control system.

5. The electric vehicle battery replacement system according to claim 4, characterized in that: The water and electricity connector (75) corresponds to the charging port of the large battery or the small battery.

6. The electric vehicle battery replacement system according to claim 5, characterized in that: The locking and unlocking mechanism (6) further comprises a Z-direction locking head (63) passing through a layer of plates (61); wherein the Z-direction locking head (63) is mounted on an I-shaped Z-direction lifting plate (66) on the back of the layer of plates (61); an electric cylinder V (67) is mounted on the back of the layer of plates (61) via an electric cylinder mounting seat (671); an output shaft of the electric cylinder V (67) is connected to the Z-direction lifting plate (66), driving the Z-direction lifting plate (66) and the Z-direction locking head (63) thereon to move up and down in a direction perpendicular to the plane of the layer of plates (61).

7. A battery replacement method, using the electric vehicle battery replacement system according to any one of claims 1 to 6, characterized in that: The steps include: Control the feeding battery to move between or on the battery rack layers, and control the large battery positioning axis or the small battery positioning axis to position the feeding battery according to the model of the feeding battery; Control the Z-axis lock, Y-axis lock and XY-axis lock to lock the feed battery; According to the model of the feeding battery, the control driving mechanism drives the slider III or the upper and lower slide seats of the water-electricity connector to remain stationary or move downward, so that the water-electricity connector is connected to the charging port of the feeding battery.

Images