Multi-power-supply selective connecting device for electric vehicle

Abstract

The invention relates to the technical field of electric vehicle power supply management, and provides a multi-power-supply selective connecting device for an electric vehicle. The device is used for realizing flexible interconnection of two or more battery packs, and comprises a connecting frame, a plurality of groups of communication contacts, a mode adjusting structure, a scale deposition layer cleaning structure and an operation mounting disc. Wherein the plurality of groups of communication contacts are symmetrically arranged on the two sides of the connecting frame and are used for being electrically connected with the end parts of the batteries; the mode adjusting structure is arranged between the communicating contact heads and comprises an adjusting disc and a plurality of contacts distributed at equal intervals, the contacts form a plurality of gear contact combinations, and the interconnection relation of different modes is achieved by adjusting wires in the disc; the scale deposition layer cleaning structure comprises a contact friction arc-shaped section and a contact friction arc-shaped section which are respectively used for cleaning scale deposition layers communicated with the contact and the contact; the device is compact in structure, small in contact resistance and long in service life, and effectively solves the problems of poor contact, difficulty in switching, difficulty in maintenance and the like in the existing device.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle power management, and in particular to a connection device for interconnecting two or more battery packs of an electric vehicle. Background Art

[0002] In the electric vehicle power supply system, multiple battery packs are usually required to be connected in series and parallel to meet the power supply requirements. Existing battery pack connection devices mainly include two types: one is a fixed connection device, in which each connection element connects the battery pack into a series and parallel structure through fixed wiring terminals; the other is a switchable connection device, in which the connection mode of the battery pack is changed by switching the switch.

[0003] The fixed connection device in the prior art has the following problems: the connection terminals and the battery contact points are prone to oxidation and fouling after long-term use, resulting in increased contact resistance; once a battery fails, it is impossible to flexibly switch to other battery packs, affecting the reliability of the entire power supply system. Although the switchable connection device can realize the switching of battery packs, its connection structure is complex and large in size, and it is easy to generate electric sparks during the switching process, causing damage to the connection points.

[0004] At the same time, these two types of devices also commonly have the following problems in actual applications: the contact resistance at the connection point is large, resulting in reduced power supply efficiency; the interconnection relationship between the connecting elements is fixed and difficult to dynamically adjust according to the battery status; the protection performance of the connecting device is poor and is easily affected by the environment; maintenance is inconvenient and frequent inspection and cleaning of the contact points are required.

[0005] Based on this, the development of a multi-power selective connection device that can achieve flexible interconnection of battery packs, has an automatic cleaning function, and has a compact structure has become an important issue at present. This is of great value to improving the performance, safety and reliability of the electric vehicle power system. Summary of the invention

[0006] The purpose of the present invention is to solve the deficiencies of the prior art. The present invention provides a multi-power selective connection device for electric vehicles, which realizes flexible switching and fault isolation of battery packs through a mode adjustment structure, and provides a fouling layer cleaning structure to automatically clean the contact surface during the switching process, thereby solving the problems of poor contact and difficult switching existing in the multi-power management of traditional electric vehicles, and providing a reliable, efficient and easy-to-use technical solution.

[0007] In order to solve the above problems, the present invention adopts the following scheme: a multi-power selective connection device for electric vehicles, comprising: a connection frame, used to connect with the frame of the electric vehicle; multiple groups of connecting contacts, symmetrically arranged on both sides of the connection frame; a mode adjustment structure, arranged between the connecting contacts, comprising: an adjustment disk, multiple contacts are evenly spaced along the circumferential direction at both ends, and the multiple contacts form a plurality of groups of gear contact combinations; the gear contact combinations realize line connections of different modes through the wires inside the adjustment disk; The fouling layer cleaning structure comprises: contact friction arc sections arranged on both sides of the adjusting disc, used to clean the fouling of the connecting contact head; contact point friction arc sections arranged on both ends of the adjusting disc, used to clean the fouling of the contact points; The operating installation disk is used to install the adjusting disk and the fouling layer cleaning structure.

[0008] Beneficial effects: The multi-power selective connection device adopts a modular design, and realizes flexible switching and fault isolation of battery packs through the mode adjustment structure. At the same time, the fouling layer cleaning structure can automatically clean the contact surface during the switching process, greatly extending the service life of the equipment. The overall structure is compact and symmetrically arranged, which is easy to install and maintain, can realize intelligent management of battery packs, and improve the reliability and service life of the system.

[0009] Preferably, the contact friction arc section is provided with a plurality of connection holes, and the connection holes correspond one-to-one with the connection contact head; the contact friction arc section is provided with a first friction surface for contacting with the connection contact head; the contact point friction arc section is provided with a second friction surface for contacting with the contact point. Beneficial effect: By setting the one-to-one corresponding connection holes and the double friction surface structure, not only the accuracy and reliability of the connection are ensured, but also the oxide layer and scale on the contact surface can be effectively removed, the contact resistance is significantly reduced, the conductivity efficiency is improved, and the stability and reliability of the power transmission are ensured.

[0010] Preferably, the operation installation disk includes two installation disks, and a cylindrical installation space for installing the adjustment disk is formed between the two installation disks; the two installation disks are provided with connecting through holes coaxial with the connection holes; the contact friction arc segment and the contact point friction arc segment are fixed in the same installation disk through positioning pins and pressure plates. Beneficial effect: The double disk structure and coaxial connecting through hole design provide a stable installation support for the adjustment disk, and the friction assembly is integrated and fixed in the installation disk through positioning pins and pressure plates, which not only improves the structural stability, but also realizes the integrated installation of components, greatly reducing the assembly difficulty and maintenance cost.

[0011] Preferably, the mounting disc is provided with an arc groove; the contact friction arc segment and the contact point friction arc segment are both arc-shaped and are mounted in the arc groove through a positioning boss; the contact point friction arc segment passes through the arc groove through a through hole to maintain a preset gap with the contact point. Beneficial effect: Through the matching design of the arc groove and the positioning boss, the friction component is accurately installed and positioned, and the preset gap is set to optimize the friction cleaning effect. The overall arc structure design is not only compact in layout, but also convenient for assembly and maintenance, and improves the practicality and maintainability of the product.

[0012] Preferably, an adjusting gear is provided on the edge of a circular end face of the adjusting disc; the adjusting gear and the gear transmission rod form a reduction transmission; the gear transmission rod is supported by a bearing and extends to the front part of the vehicle. Beneficial effects: the reduction gear transmission mechanism is adopted and the control is extended to the front part of the vehicle, and more precise adjustment control is provided through the reduction transmission, and the bearing support improves the stability and service life of the transmission. This remote control design not only facilitates the control of the operator, but also improves the convenience of use and control accuracy of the entire system.

[0013] Preferably, the edge of the operating mounting plate is provided with a protruding connection block; the protruding connection block is connected to a pulling rope; the pulling rope is connected to the starting operating component of the front part of the vehicle after being guided by the guide wheel group. Beneficial effect: Through the design of the pulling rope and the guide wheel group, the fast operation function of mode switching is realized, and the setting of the guide wheel group ensures the smoothness of transmission. This design provides the driver with a simple and intuitive operation method, greatly improving the convenience and operability of mode switching.

[0014] Preferably, the outer wall of the adjustment disk has connection areas distributed at equal intervals along the circumference; the outer wall of the adjustment disk is provided with two sets of electrical connection devices, including electrical connection lines and electrical contact blocks; the connection areas are used to contact or disconnect with the electrical contact blocks. Beneficial effect: The design of connection areas with equal intervals and two sets of electrical connection devices not only ensures the uniformity and reliability of the switching process, but also improves the redundancy of the system. This design realizes the controllable connection and disconnection of the circuit, facilitates the flexible switching of different power supply modes, and improves the reliability and adaptability of the system.

[0015] Preferably, the outer peripheral wall of the adjustment disc is also provided with a power-off friction zone, which is arranged alternately with the connection zone; the power-off friction zone is provided with a third friction surface for removing oxides and scale on the surface of the electrical contact block. Beneficial effect: By arranging the power-off friction zone and the connection zone alternately and adding the third friction surface, the automatic switching of the power supply and cleaning functions is realized. This design can not only effectively remove oxides and scale on the surface of the electrical contact block and extend the service life, but also improve the reliability of the electrical connection and ensure the long-term stable operation of the system.

[0016] Preferably, the surface of the connecting contact head is coated with a conductive elastic layer; the conductive elastic layer is one of a graphene composite material, a conductive polymer material or a metal elastic material. Beneficial effect: By coating the surface of the connecting contact head with a conductive elastic layer and providing a variety of material selection options, good contact performance is ensured and flexibility in material selection is provided. This design not only improves the conductive efficiency and connection reliability, but also has good wear resistance and prolongs the service life of the equipment.

[0017] Preferably, it further comprises: a protective baffle fixed to the connecting frame by bolts; the protective baffle is provided with through holes, and the through holes are arranged in a plum blossom or fan-shaped opening. Beneficial effect: By setting the protective baffle and the reasonably arranged through hole design, while providing good protection effect, it is also convenient for heat dissipation and wiring operation of the equipment. The bolt fixing method is convenient for disassembly and maintenance, and the overall protection performance is good, which improves the safety and maintainability of the equipment.

[0018] Compared with the prior art, the technical solution of the present invention has the following advantages: The multi-power selective connection device provided by the present invention realizes flexible switching and fault isolation of battery packs through a mode adjustment structure, and can automatically select the optimal connection mode according to the battery status to ensure continuous and reliable power supply of the system; the provided scale layer cleaning structure and triple friction surface design form an all-round cleaning mechanism, which can automatically clean the contact surface during the switching process, effectively reduce the contact resistance, and improve the conductive efficiency; the modular and symmetrical structural design is adopted, and the double disc structure and coaxial design are matched to improve the accuracy and stability of the connection, making the structure compact and easy to install and maintain; by extending the remote control mechanism to the front of the vehicle and providing a pulling rope and a guide wheel group, it is convenient for the driver to perform fast mode switching operations, and the reduction transmission mechanism provides precise adjustment control; the protective baffle and the sealing structure are provided to provide reliable environmental protection, and have multiple safety protection functions such as anti-reverse connection and overcurrent protection; the key components are made of wear-resistant materials and are designed with multiple sealing protection measures to ensure long-term and reliable operation of the device; the overall structural design is reasonable, the manufacturing cost is controllable, it is suitable for various types of electric vehicles, and the parameters and configurations can be flexibly adjusted according to actual needs, and it has broad application prospects. Through the organic combination of the above-mentioned technical features, the present invention not only solves the problems of poor contact and difficult switching in the multi-power management of traditional electric vehicles, but also provides a reliable, efficient and easy-to-use solution with significant technological advancement. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the figures required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the figures described below are only some embodiments of the present application. For ordinary technicians in this field, other figures can be obtained based on these figures without paying creative work.

[0020] Figure 1 It is a structural schematic diagram of the present invention when applied to an electric vehicle frame; Figure 2 It is a schematic diagram of the internal structure of the switching device of the present invention in cooperation with the battery pack; Figure 3 for Figure 2 A partial enlarged view of point Ⅰ in the middle; Figure 4 It is a structural schematic diagram of the mode adjustment structure of the present invention; Figure 5 It is a structural schematic diagram of the fouling layer cleaning structure of the present invention being installed on the operating mounting member; Figure 6 It is a structural schematic diagram of the fouling layer cleaning structure of the present invention; Figure 7 It is a schematic structural diagram of the connection between the adjusting disc and the electrical contact block of the present invention.

[0021] Reference numerals: vehicle frame 10, main support tube 11, side support assembly 12, mounting position 121, mounting box 13, controller 14, rear shock absorber 15, connecting bracket 16, main leg 17, steering support frame 18, battery pack 21, external connecting wire 22, connecting frame 30, multi-power selective connecting device 40, connecting contact head 41, mode adjustment structure 42, fouling layer cleaning structure 43, operation installation disk 44, adjustment disk 421, gear contact assembly 422, contact 4221, contact friction arc segment 431, first friction Friction surface 4311, connection hole 4312, contact friction arc segment 432, second friction surface 4321, mounting disc 441, connecting through hole 4411, arc groove 4412, mounting space 442, protruding connection block 443, pulling rope 444, protective baffle 45, adjusting gear 51, gear transmission rod 52, making way gap 53, electrical connection line 61, electrical contact block 62, elastic member 63, connecting area 71, power-off friction area 72, third friction surface 721, placement shell 80, arc gap 81, electrical conduction line 90. DETAILED DESCRIPTION

[0022] The following will be combined Figure 1-Figure 7The preferred embodiments of the present invention are described in detail. It should be noted that the following description is only a preferred embodiment of the present invention, rather than a limitation of the present invention. Those skilled in the art should understand that various modifications and variations can be made to the present invention without departing from the spirit and scope of the present invention. The scope of protection of the present invention shall be subject to the attached claims.

[0023] Embodiment 1: refer to Figure 1 , this embodiment provides a multi-power selective connection device 40 and a battery monitoring system for an electric vehicle, which is fixed below the main support tube 11 of the frame through a specific mounting bracket. The multi-power selective connection device 40 is installed in the frame 10 of the two-wheeled electric vehicle, the frame 10 is connected to the steering support frame 18, the frame 10 includes a main support tube 11 connected to the steering support frame 18, and the main support tube 11 is connected to multiple groups of symmetrical side bracket groups 12 on both sides along the width direction of the electric vehicle. Among them, the side bracket group 12 is made of a hollow steel pipe, the diameter of the main support tube is 30-40mm, and the diameter of the secondary support tube is 20-25mm. The bracket groups are fixedly connected by welding, and reinforcing ribs are added at key nodes. Multiple groups of side bracket groups 12 are arranged in a three-sided surrounding shape, and a mounting position 121 for placing a battery is formed. A waterproof mounting box body 13 is arranged in the mounting position 121. The mounting box body 13 has a drainage hole and a ventilation structure, and a shockproof pad is arranged inside. The battery is installed in the mounting box body 13.

[0024] refer to Figure 1-Figure 3 The battery system consists of four 12V batteries, which are arranged in a field shape, and the four batteries are divided into two battery groups 21 with the symmetry axis consistent with the travel direction of the electric vehicle as the boundary. The spacing distance between the two battery groups 21 is 30-50mm, forming a space for air circulation and device installation. This spacing design has a dual function: on the one hand, it improves the heat dissipation effect of the battery through forced convection; on the other hand, it reserves space for the installation of a multi-power selective connection device 40. The multi-power selective connection device 40 is placed in the center position between the two battery groups 21, and is fastened to the electric vehicle frame 10 through the connecting frame 30 on its upper part. Each battery is equipped with an external connection line 22 of standard specifications, and a waterproof electrical connector is set at the end of the external connection line 22. The electrical connector adopts a quick plug-in design and can be reliably separated and connected with the multi-power selective connection device 40.

[0025] refer to Figure 2-Figure 4 The multi-power selective connection device 40 is mainly composed of four groups of connection contacts 41, a mode adjustment structure 42, a fouling layer cleaning structure 43, and an operation installation disk 44. Its structural features are as follows: 1. Connection contact layout: Each group of connection contacts 41 and the fouling layer cleaning structure 43 are symmetrically arranged on both sides of the mode adjustment structure 42. Each group of connection contacts 41 is made of gold-plated copper alloy. The four connection contacts 41 on each side include two positive electrodes and two negative electrodes, and their contact area is not less than 12mm².

[0026] 2. Electrode connection: Each positive electrode or negative electrode is reliably connected to the corresponding battery electrode through the waterproof electrical connector of the external connection line 22, and the contact resistance is not greater than 0.5mΩ.

[0027] 3. Movement mechanism: The mode adjustment structure 42 and the fouling layer cleaning structures 43 on both sides adopt a coaxial self-rotation connection mode, and the rotation torque is not greater than 0.8N•m.

[0028] 4. Spatial layout: The four connecting contacts 41 on each side are distributed in an equally divided circular arc shape.

[0029] The number of groups of connecting contacts 41 of the device can be flexibly configured according to the actual number of batteries and symmetrically distributed on both sides of the mode adjustment structure 42.

[0030] The mode adjustment structure 42 includes the following key components: 1. Adjusting disc 421: Made of wear-resistant engineering plastics, with dimensions such as diameter 80-100 mm and thickness 15-20 mm.

[0031] 2. Contact distribution: Multiple contacts 4221 are evenly distributed along the circumferential direction at both ends of the adjustment disk 421 (only the contacts at one end of the adjustment disk are shown in the figure). The contacts are made of silver-plated copper alloy, and the contact resistance is not greater than 0.3mΩ.

[0032] 3. Shift combination: Multiple contacts 4221 form several shift contact combinations 422, and the contacts 4221 of each shift contact combination 422 are symmetrically distributed at both ends of the adjustment disk 421. The number of contacts in each group matches the number of connected contact heads 41, and reliable separation contact can be achieved.

[0033] 4. Circuit design: Each position contact combination 422 corresponds to a different battery series connection state, and different modes of line connection are achieved by adjusting the wire inside the disc 421 (cross-sectional area not less than 2.5mm²). The contact 4221 can be reused in different position contact combinations 422 to improve space utilization. (The line connection is not shown in the figure).

[0034] By setting the mode adjustment structure, when one of the four batteries is abnormal (voltage is lower than 10.5V or current fluctuation exceeds ±20% of the rated value), the adjustment disc 421 can be rotated (the rotation angle is 0-360°, step-by-step rotation, 45° per step) to make the connecting contact head 41 and the gear contact combination 422 that meets the requirements contact and conduct, thereby realizing the reorganization connection of the battery pack. The rotation of the adjustment disc 421 is driven by a stepper motor to ensure that the positioning accuracy is within ±0.5° and the contact pressure of the contact point is maintained within the range of 0.6-0.8MPa.

[0035] refer to Figure 3 , Figure 5-Figure 6 The fouling layer cleaning structure 43 includes two contact friction arc segments 431 for cleaning the fouling of the two-side connecting contact heads 41 and two contact friction arc segments 432 for cleaning the fouling of the two-side contacts 4221, which are installed on both sides of the operation installation disk 44. The two contact friction arc segments 431 and the two contact friction arc segments 432 are symmetrical to both sides of the adjustment disk 421, and are located between the adjustment disk 421 and the connecting contact heads 41 on the corresponding side thereof to maintain a working gap. The contact friction arc section 431 is made of high hardness material, such as tungsten carbide material (hardness not less than HRA90), and is provided with four connection holes 4312 through which four connecting contacts 41 can pass one by one. The contact friction arc section 431 is provided with a first friction surface 4311 (surface roughness Ra value 0.8-1.2μm) that can contact the connecting contact 41, and the contact point friction arc section 432 is provided with a second friction surface 4321 (using the same surface treatment process) that contacts the contact point 4221. All friction contact surfaces are treated with anti-oxidation, and the service life is not less than 10,000 reciprocating movements.

[0036] In this scheme, by rotating the operating mounting disk 44, the two first friction surfaces 4311 on the two contact friction arc segments 431 and the connecting contact head 41 generate relative motion friction; by rotating the adjusting disk 421, the second friction surfaces 4321 on the two contact friction arc segments 432 and the contacts 4221 at both ends of the adjusting disk 421 are rubbed and cleaned. This design effectively solves the problem of fouling layer generated by factors such as environmental oxidation and spark corrosion during frequent switching between the connecting contact head 41 and the contact 4221. Through automatic cleaning or regular friction cleaning during switching, the surface roughness of the contact can be maintained below Ra 1.6μm, and the contact resistance can be controlled within 0.5mΩ, effectively ensuring the conductive performance of the connecting contact head 41 and the contact 4221. This active cleaning mechanism can avoid the increase in contact resistance caused by the thickening of the fouling layer, thereby extending the service life of the battery (expected to increase by 30-50%) and ensuring a stable power supply effect (voltage fluctuation ≤±2%).

[0037] Furthermore, the remaining space of the contact friction arc section 431 except the connection hole 4312 is designed with a retention space, which can completely accommodate a connection contact head 41. This design makes the adjustment disc 421 have a dual function: on the one hand, it removes dirt through surface friction (friction force 3-5N); on the other hand, the adjustment disc 421 can be accurately positioned by stepping rotation so that each connection contact head 41 is completely in the space, thereby reliably isolating the contact between the connection contact head 41 and the contact 4221 (insulation resistance>100MΩ). This isolation mechanism ensures that the battery can be in a completely disconnected state, and the leakage current is less than 1mA, which provides safety for system maintenance and battery replacement. The rotation positioning can adopt a ratchet structure with a self-locking function and a positioning accuracy of ±0.5° to prevent accidental contact.

[0038] Furthermore, the inner wall of the connection hole 4312 is chamfered at 15° (chamfer depth 0.5-0.8mm), and the surface is anodized to ensure wear resistance. The end of the connection contact head 41 close to the contact 4221 is designed to be spherical and plated with a 3-5μm gold layer to improve conductivity. Through this optimized design, the friction coefficient of the connection contact head 41 when sliding into or out of the connection hole 4312 is controlled between 0.1-0.15, and the operating force does not exceed 5N, ensuring a smooth and reliable conversion process.

[0039] Furthermore, the surface of the connecting contact head 41 is coated with a conductive elastic layer (thickness 0.2-0.3 mm), and the conductive elastic layer can be made of the following materials: 1. Graphene composite materials: volume resistivity ≤10^-3 Ω·cm, elastic deformation 20-30% 2. Conductive polymer materials: such as doped PEDOT:PSS, conductivity>1000 S / cm 3. Metal elastic materials: such as beryllium copper alloy, yield strength ≥500MPa This embodiment uses a graphene composite material, which is composed of multi-layer graphene (8-12 layers) and elastomer (silicone rubber), and has excellent conductivity (lateral conductivity>5000 S / cm) and mechanical properties. When the connection contact head 41 slides into the connection hole 4312, the conductive elastic layer generates an elastic pressure of 2-3N to ensure stable contact with the contact 4221 (contact resistance <0.3mΩ), thereby achieving reliable power transmission (allowing instantaneous current ≥100A).

[0040] In order to make the installation of the mode adjustment structure 42 and the fouling layer cleaning structure 43 compact, refer to Figure 2-Figure 3The operation installation disk 44 is symmetrically designed and includes two installation disks 441 formed by precision injection molding. A cylindrical installation space 442 (e.g., diameter 82-85mm, axial play 0.2-0.3mm) is formed between the two installation disks 441 to install the adjustment disk 421, and an annular sealing groove (e.g., depth 1.5mm, width 2mm) is provided on the inner wall of the space for installing the sealing ring. The two installation disks 441 are precisely machined to have connecting through holes 4411 (aperture tolerance H7) with a coaxiality error of less than 0.05mm with the four connecting holes 4312.

[0041] The contact friction arc segment 431 and the contact point friction arc segment 432 are installed in the same mounting disk 441 by means of positioning pins (Φ3h6) and pressure plates. This integrated design has multiple advantages: on the one hand, it realizes the precise coaxial installation and compact arrangement of the contact friction arc segment 431 and the contact point friction arc segment 432, and forms dust and water-proof protection (protection level IP54) for the contact point 4221 on the adjusting disk 421 through the lip sealing ring, effectively avoiding the deposition of environmental pollutants (particle size>10μm) on the surface of the contact point 4221; on the other hand, the synchronous rotation (speed ratio 1:1) of the contact friction arc segment 431 and the contact point friction arc segment 432 can be realized through the single-point drive operation mounting disk 44 (torque 1.2-1.5N·m), and the cleaning operation of the fouling layer is made more efficient and reliable with the ratchet positioning mechanism.

[0042] Furthermore, the mounting disc 441 is provided with an arc groove 4412 (groove depth 4-5mm, arc radius 35-40mm, groove width matches the thickness of the friction disc, and matching clearance 0.05-0.1mm), and the contact friction arc segment 431 and the contact point friction arc segment 432 are both precision-machined arc shapes (arc span 120°, thickness 3±0.02mm), and are precisely installed in the arc groove 4412 through a positioning boss (height 2mm). The contact point friction arc segment 432 passes through the arc groove 4412 through a precision-machined through hole (aperture tolerance H7) and maintains a working clearance of 0.2-0.3mm with the contact 4221. This structural design makes the installation of the contact friction arc segment 431 and the contact point friction arc segment 432 more compact (total thickness does not exceed 12mm), ensuring that the overall layout size of the battery and multi-power selective connection device 40 is controlled within the range of 100×80×40mm.

[0043] To facilitate the rotation of the adjustment disk 421, refer to Figure 2-Figure 4, a circular end face edge of the adjustment disc 421 is integrated with a complete circumference adjustment gear 51 (parameters can be: module 1.5, number of teeth 40, pressure angle 20°, tooth width 8mm), and the adjustment gear 51 adopts precision carburizing and quenching process (surface hardness HRC58-62). The gear and the gear transmission rod 52 made of 20CrMnTi (parameters can be: module 1.5, number of teeth 20) form a reduction transmission (transmission ratio 2:1), and the gear pair side clearance is controlled at 0.1-0.15mm. The gear transmission rod 52 is supported by deep groove ball bearings (6202-2Z) at both ends, passes through the main support tube 11 (axial movement ≤0.5mm) and extends to the front part of the car, and is splined to the adjustment operating component at the front of the car (SAE spline, 6 teeth).

[0044] When adjusting the battery connection mode, the operator drives the gear transmission rod 52 to rotate through the adjustment operating component of the front of the vehicle (operation torque requirement ≤ 2N·m), and the transmission mechanism amplifies the torque and drives the adjustment disk 421 to rotate precisely (division accuracy ±1°), thereby realizing reliable switching of the battery connection mode. The drive of the adjustment disk 421 can be any one of the existing technologies.

[0045] Furthermore, the diameter of the mounting disc 441 is designed to be larger than the diameter of the adjusting disc 421, and the mounting disc 441 near the adjusting gear 51 is designed with a 45° fan-shaped clearance notch 53 (the depth matches the gear module). A sealing lip (made of nitrile rubber, 1 mm thick) is provided on the edge of the notch to provide dustproof effect while ensuring the meshing of the gears.

[0046] The above design forms IP54 protection for the adjustment disc 421 by installing the disc 441, and combined with the precise design of the clearance notch 53, it not only ensures the reliable meshing transmission (coefficient of overlap 1.2-1.4) between the adjustment gear 51 and the gear transmission rod 52, but also minimizes the possibility of dust intrusion (seal ring compression rate 15-20%). The service life of the entire transmission system is not less than 10,000 switching cycles.

[0047] To facilitate the rotation of the mounting plate 44, refer to Figure 2-Figure 3 The operation mounting plate 44 also includes a protruding connection block 443 (made of aluminum alloy 6061-T6, with anodized surface) connected at the edges of the two mounting discs 441 by high-strength bolts (strength grade 8.8), and the protruding connection block 443 is provided with a positioning groove (depth 3mm, fillet R1) for fixing the wire rope. The protruding connection block 443 is connected to a high-strength pulling rope 444 through a special ferrule, and the pulling rope 444 is reliably connected to the starting operating component of the front part of the vehicle after being guided by a guide wheel group (using a sealed bearing 6000-2RS).

[0048] To realize the battery power supply to electric vehicles, refer to Figure 2-Figure 4 , Figure 7 The outer wall of the adjusting disc 421 has connecting areas 71 distributed at equal intervals of 45° along the circumferential direction. The connecting areas 71 are made of composite conductive material, and the following solutions can be selected: 1. Metal material: gold-plated copper alloy, conductivity ≥ 90% IACS 2. Semiconductor material: doped silicon-based material, resistivity ≤ 0.01 Ω·cm 3. Carbon-based materials: graphene composite materials, surface resistance <0.1 Ω This embodiment uses gold-plated copper alloy (purity ≥ 99.9%, coating thickness 3-5μm). The outer wall of the adjustment disc 421 is provided with two sets of electrical connection devices, such as an electrical connection wire 61 with a specification of 16mm² and an electrical contact block 62 made of silver-plated copper alloy (purity ≥ 99.9%). One set of connection devices is connected to the motor and various sensors at the rear of the vehicle through a flame-retardant cable trough (temperature resistance 125℃), and the other set of connection devices leads to low-power devices such as the LCD display screen (power consumption ≤ 2W) at the front of the vehicle.

[0049] This setting can achieve reliable contact (contact resistance ≤ 0.2mΩ) or disconnection between the connection area 71 and the electrical contact block 62 by precisely rotating the adjustment disk 421 (angle error ≤ ±1°). When temporary power failure is required, aligning the non-conductive area with the electrical contact block 62 can effectively reduce standby power consumption (≤ 0.1W).

[0050] Furthermore, the outer peripheral wall of the adjustment disc 421 is also provided with a power-off friction zone 72, which is arranged alternately with the connection zone 71 (with a spacing of 22.5 degrees). The power-off friction zone 72 is made of a special composite material (tungsten carbide matrix, hardness HRA90), and its surface is processed with a third friction surface 721 formed by fine grooves (depth 0.1mm, spacing 0.5mm), which can effectively remove oxides and scale (thickness ≤ 0.05mm) on the surface of the electrical contact block 62.

[0051] To ensure contact reliability, the electrical contact block 62 is flexibly connected to the electrical connection line 61 through a gold-plated (thickness 2-3 μm) elastic member 63 (elastic coefficient 10 N / mm). The elastic member 63 provides a contact pressure of 2-3 N to ensure stable contact resistance.

[0052] All electrical connection wires 61 are zoned and installed in a housing 80 with a flame retardant grade of V0. The arc-shaped notch 81 (arc radius 42mm) of the housing 80 is interference-fitted with the mounting disc 441 (interference amount 0.1-0.2mm) to achieve IP54 protection. At the same time, the electrical conductive wires 90 (cross-sectional area 2.5mm²) of the monitoring system also adopt the same protection scheme.

[0053] In order to protect the core functional components, a 2mm thick protective baffle 45 (PC / ABS material, flame retardant grade V0) is designed, which can be fixed to the connecting frame 30 by four M4 bolts. The through holes on the baffle are arranged in plum blossom shape (aperture 12mm, spacing 30mm) or 120° fan-shaped opening (radius 25mm) to ensure the convenience of wiring.

[0054] The working principle of switching the power supply battery and cleaning the fouling layer in this embodiment: First, operate the starting operating component of the front part of the vehicle, and drive the two mounting discs 441 to rotate synchronously by pulling the pull rope 444 (stroke 15-20mm). This action allows the connecting contact head 41 to accurately slide into the corresponding connection hole 4312 and the connecting through hole 4411 at a speed of 0.2-0.3m / s (positioning accuracy ≤0.1mm), achieving reliable contact between the connecting contact head 41 and the contact 4221 (contact pressure 0.6-0.8MPa). At this time, the monitoring system collects the working status of the four batteries in real time through high-precision voltage sensors (resolution ±0.01V) and current sensors (range 0-100A, accuracy 0.5%). Based on the collected data, the system selects the optimal battery connection mode. Subsequently, the gear transmission rod 52 is driven to rotate (rotation speed 60-120 rpm) through the adjustment operating component of the front part (maximum operating torque 2 N·m), driving the adjustment disk 421 to accurately rotate to the target position (positioning accuracy ±1°), so that the appropriate gear contact combination 422 forms a stable contact with the connecting contact head 41 (contact resistance ≤ 0.3 mΩ).

[0055] The monitoring system uses a 32-bit microprocessor to continuously monitor the key parameters of each battery (voltage 10.5-14.4V, charge and discharge current -50A to +50A, temperature -20℃ to 60℃, internal resistance 5-15mΩ). When it detects abnormal conditions such as battery voltage below 10.5V, temperature exceeding 55℃, discharge current exceeding 45A, or internal resistance mutation exceeding 30%, protection is triggered; when the pulling rope 444 is pulled, the two mounting discs 441 are driven to rotate synchronously through a precision transmission mechanism (back clearance ≤0.1mm), and the rotation of the mounting disc 441 drives the integrated contact friction arc section 431 to move together, and the surface of the connecting contact head 41 is cleaned at a pressure of 0.6-0.8MPa. This active cleaning mechanism can remove scale caused by oxidation and spark corrosion (usually with a thickness of 0.02-0.05mm), and keep the contact resistance below 0.5mΩ at all times, ensuring stable power transmission efficiency (≥99.5%) and equipment service life.

[0056] The working modes of the gear contact combination design include normal working mode (48V, four batteries are connected in series, T1-T2 is connected to battery 1, T3-T4 is connected to battery 2, T5-T6 is connected to battery 3, T7-T8 is connected to battery 4, the working voltage is 48V, that is, 12V×4), emergency mode 1 (36V, three batteries are connected in series, that is, the faulty battery is skipped, T1-T2 is connected to battery 1, T3-T4 is connected to battery 2, T5-T6 is connected to battery 3, T7-T8 is disconnected, the working voltage is 36V, that is, 12V×3), emergency mode 2 (24V, two batteries are connected in series, T1-T2 is connected Connect battery 1, T3-T4 connect battery 2, T5-T8 are all disconnected, the working voltage is 24V (i.e. 12V×2) and diagnostic mode (detect the status of each battery individually, and any battery can be connected individually for battery performance detection and maintenance); special design considerations include that each set of contacts has polarity identification, there is an anti-reverse connection protection mechanism, there is enough safety distance between the contacts to prevent short circuit, and the cleaning structure can cover all contact positions; the switching mechanism design adopts unidirectional rotation of the adjustment disc to avoid poor contact, there is an overlapping area when the contacts transition to ensure continuous power supply, and the gears have clear identification and positioning structure.

[0057] It should be noted that the specific parameters involved in the present invention are all preferred implementation methods, not the only limiting values. For example, the voltage value of the battery can be selected from other specifications according to actual needs, and the connection method can also be flexibly adjusted according to the actual use scenario; the safety distance between the contacts can be appropriately adjusted according to the actual working voltage level, but it should ensure compliance with relevant electrical safety standards; the specific size and pressure of the friction cleaning structure can be adaptively adjusted according to the contact material and the use environment; the reduction ratio and operating torque of the transmission mechanism can be optimized according to the actual operation convenience requirements; the sampling frequency and accuracy of the monitoring system can be adjusted according to the requirements of the specific application scenario. The specific parameters and design schemes in this embodiment are mainly optimized based on the use environment and performance requirements of the two-wheeled electric vehicle. Under the premise of ensuring safety and reliability, the various parameters can be reasonably adjusted according to different application scenarios.

Claims

1. A multi-power selective connection device for an electric vehicle, characterized in that: include: A connecting frame, used for connecting with the frame of the electric vehicle; A plurality of groups of connecting contacts are symmetrically arranged on both sides of the connecting frame; The mode adjustment structure is arranged between the connecting contacts, and comprises: an adjustment disk, a plurality of contacts are evenly spaced along the circumferential direction at both ends, and the plurality of contacts form a plurality of groups of gear contact combinations; the gear contact combinations realize line connection of different modes through the wires inside the adjustment disk; The fouling layer cleaning structure comprises: contact friction arc sections arranged on both sides of the adjusting disc, used to clean the fouling of the connecting contact head; contact point friction arc sections arranged on both ends of the adjusting disc, used to clean the fouling of the contact points; The operating installation disk is used to install the adjusting disk and the fouling layer cleaning structure.

2. The multi-power selective connection device for electric vehicles according to claim 1, characterized in that: The contact friction arc section is provided with a plurality of connection holes, and the connection holes correspond one to one with the connection contact heads; The contact friction arc section is provided with a first friction surface for contacting the connecting contact head; The contact point friction arc section is provided with a second friction surface for contacting the contact point.

3. The multi-power selective connection device for electric vehicles according to claim 2, characterized in that: The operation installation disk includes two installation disks, and a cylindrical installation space for installing the adjustment disk is formed between the two installation disks; The two mounting discs are provided with connecting through holes coaxial with the connecting holes; The contact friction arc segment and the contact point friction arc segment are fixed in the same mounting disc through positioning pins and a pressure plate.

4. The multi-power selective connection device for electric vehicles according to claim 3, characterized in that: The mounting disc is provided with an arc groove; the contact friction arc segment and the contact point friction arc segment are both arc-shaped and are installed in the arc groove through a positioning boss; the contact point friction arc segment penetrates the arc groove through a through hole to maintain a preset gap with the contact point.

5. The multi-power selective connection device for electric vehicles according to claim 1, characterized in that: An adjusting gear is provided on the edge of a circular end surface of the adjusting disc; The adjusting gear and the gear transmission rod form a reduction transmission; The gear transmission rod is supported by a bearing and extends to the front part of the vehicle.

6. The multiple power selective connection device for electric vehicles according to claim 1, characterized in that: The edge of the operation installation plate is provided with a protruding connection block; The protruding engagement block is connected with a pulling rope; The pulling rope is connected with the starting operation component of the vehicle front part after being guided by the guide wheel group.

7. The multi-power selective connection device for electric vehicles according to claim 1, characterized in that: The outer peripheral wall of the regulating disc has connected areas distributed at equal intervals along the circumferential direction; The outer peripheral wall of the adjusting disc is provided with two sets of electrical connection devices, including electrical connection wires and electrical contact blocks; The communication area is used for contacting or disconnecting with the electrical contact block.

8. The multiple power selective connection device for electric vehicles according to claim 7, characterized in that: The outer peripheral wall of the regulating disc is also provided with a power-off friction zone, which is arranged alternately with the communication zone; The power-off friction zone is provided with a third friction surface for removing oxides and scale deposits on the surface of the electrical contact block.

9. The multiple power selective connection device for electric vehicles according to claim 2, characterized in that: The surface of the connecting contact head is wrapped with a conductive elastic layer; The conductive elastic layer is one of a graphene composite material, a conductive polymer material or a metal elastic material.

10. The multi-power selective connection device for electric vehicles according to claim 1, characterized in that: Also includes: A protective baffle, fixed to the connecting frame by bolts; The protective baffle is provided with through holes, and the through holes are arranged in a plum blossom shape or fan-shaped openings.

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