Multi-power Selective Connection Device for Electric Vehicles

Abstract

The present invention relates to the technical field of electric vehicle power management, and provides a multi-power selective connection device for electric vehicles. This device is used to achieve flexible interconnection of two or more battery packs, and includes a connection frame, multiple groups of connecting contacts, a mode adjustment structure, a scale deposit cleaning structure, and an operation and installation disk. Among them, multiple groups of connecting contacts are symmetrically arranged on both sides of the connection frame and are used for electrically connecting with the ends of the batteries; the mode adjustment structure is arranged between the connecting contacts and includes an adjustment disk with multiple contacts evenly distributed at equal intervals. These contacts form several groups of gear contact combinations, and different mode interconnection relationships are realized through the wires inside the adjustment disk; the scale deposit cleaning structure includes a contact friction arc section and a contact point friction arc section, which are respectively used to clean the scale deposits on the connecting contacts and the contact points; the device has a compact structure, a small contact resistance, and a long service life, effectively solving the problems of poor contact, difficult switching, and difficult maintenance existing in the existing devices.

Description

Technical Field

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

[0002] In the power supply system of electric vehicles, it is usually necessary to connect multiple battery packs in series and parallel to meet the power supply requirements. The existing battery pack connection devices mainly include two categories: one is a fixed connection device, where each connection element connects the battery packs into a series-parallel structure through fixed wiring terminals; the other is a switchable connection device, which changes the connection mode of the battery packs through a switching switch.

[0003] The following problems exist in the fixed connection devices in the prior art: the contact points between the wiring terminals and the batteries are prone to oxidation and fouling after long-term use, resulting in an increase in contact resistance; once a certain 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 achieve the switching of battery packs, its connection structure is complex, the volume is large, and electric sparks are easily generated during the switching process, causing damage to the connection points.

[0004] At the same time, the following problems generally exist in the actual application of these two types of devices: the contact resistance at the connection points is large, resulting in a reduction in power supply efficiency; the interconnection relationship between the connection elements is fixed, making it difficult to dynamically adjust according to the battery state; the protection performance of the connection device is poor, and it is easily affected by the environment; maintenance is inconvenient, and the contact points need to be frequently inspected and cleaned.

[0005] Based on this, researching and developing a multi-power selective connection device that can achieve flexible interconnection of battery packs, has an automatic cleaning function, and is structurally compact has become an important topic at present, which has important value for improving the performance and safety 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 sets a fouling layer cleaning structure to automatically clean the contact surface during the switching process, solving the problems of poor contact and difficult switching existing in the traditional multi-power management of electric vehicles, and providing a reliable, efficient, and easy-to-use technical solution.

[0007] To solve the above problems, the present invention adopts the following solution: A multi-power selective connection device for an electric vehicle, comprising: a connection frame for connecting with the frame of the electric vehicle; multiple groups of communication contacts symmetrically arranged on both sides of the connection frame; a mode adjustment structure arranged between the communication contacts, including: an adjustment disc with a plurality of contacts evenly distributed along the circumferential direction at both ends, and the plurality of contacts form several groups of gear contact combinations; the gear contact combinations realize circuit connections in different modes through the wires inside the adjustment disc;

[0008] A fouling layer cleaning structure, including: contact friction arc segments arranged on both sides of the adjustment disc for cleaning the fouling of the communication contacts; contact point friction arc segments arranged at both ends of the adjustment disc for cleaning the fouling of the contact points;

[0009] An operation and installation disc for installing the adjustment disc and the fouling layer cleaning structure.

[0010] Beneficial effects: The multi-power selective connection device adopts a modular design, realizes flexible switching and fault isolation of the battery pack through the mode adjustment structure, and at the same time, the provided fouling layer cleaning structure can automatically clean the contact surface during the switching process, greatly extending the service life of the device. The overall structure is compact and symmetrically arranged, facilitating installation and maintenance, capable of realizing intelligent management of the battery pack, and improving the reliability and service life of the system.

[0011] Preferably, the contact friction arc segment is provided with a plurality of through holes, and the through holes correspond to the communication contacts one by one; the contact friction arc segment is provided with a first friction surface for contacting the communication contacts; the contact point friction arc segment is provided with a second friction surface for contacting the contact points. Beneficial effects: By setting the one-to-one corresponding through holes and the double friction surface structure, not only the accuracy and reliability of the connection are ensured, but also the oxide layer and fouling on the contact surface can be effectively removed, significantly reducing the contact resistance, improving the conduction efficiency, and ensuring the stability and reliability of the electric energy transmission.

[0012] Preferably, the operation and installation disc includes two installation discs, and a cylindrical installation space for installing the adjustment disc is formed between the two installation discs; the two installation discs are provided with connection through holes coaxial with the through holes; the contact friction arc segment and the contact point friction arc segment are fixed in the same installation disc through positioning pins and pressing plates. Beneficial effects: Adopting the double-disc structure and the coaxial connection through hole design provides stable installation support for the adjustment disc. At the same time, integrating and fixing the friction components in the installation disc through positioning pins and pressing plates not only improves the structural stability but also realizes the integrated installation of components, greatly reducing the assembly difficulty and maintenance cost.

[0013] Preferably, the mounting disc is provided with an arc-shaped groove; both the contact friction arc segment and the contact point friction arc segment are in a circular arc shape and are installed in the arc-shaped groove through positioning bosses; the contact point friction arc segment penetrates through the arc-shaped groove through a through hole to maintain a preset gap with the contact point. Beneficial effects: Through the combined design of the arc-shaped groove and the positioning bosses, precise installation and positioning of the friction assembly are achieved, and the preset gap optimizes the friction cleaning effect. The overall arc-shaped structure design not only makes the layout compact but also facilitates assembly and maintenance, improving the practicability and maintainability of the product.

[0014] Preferably, an adjusting gear is provided at the edge of a circular end face of the adjusting disc; the adjusting gear forms a speed-reducing transmission with the gear transmission rod; the gear transmission rod is supported by a bearing and extends to the front part of the vehicle head. Beneficial effects: By adopting a speed-reducing gear transmission mechanism and extending the control to the front part of the vehicle head, more precise adjustment and control are provided through the speed-reducing transmission, and the bearing support improves the stability and service life of the transmission. This remote control design not only facilitates the operation of the operator but also improves the usability and control accuracy of the entire system.

[0015] Preferably, a protruding connecting block is provided at the edge of the operation mounting disc; the protruding connecting block is connected with a pulling rope; the pulling rope is guided by a guide pulley group and then connected with the starting operation component of the front part of the vehicle head. Beneficial effects: Through the design of the pulling rope and the guide pulley group, the quick operation function of mode switching is realized, and the setting of the guide pulley group ensures the smoothness of the transmission. This design provides a simple and intuitive operation method for the driver, greatly improving the convenience and operability of mode switching.

[0016] Preferably, communication areas are distributed at equal intervals along the circumferential direction on the outer peripheral wall of the adjusting disc; two groups of electrical connection devices are provided on the outer peripheral wall of the adjusting disc, including electrical connection lines and electrical contact blocks; the communication areas are used for contacting or disconnecting with the electrical contact blocks. Beneficial effects: By adopting the design of communication areas distributed at equal intervals and two groups of electrical connection devices, not only the uniformity and reliability of the switching process are ensured, but also the redundancy of the system is improved. This design realizes the controllable connection and disconnection of the circuit, facilitating the flexible switching of different power supply modes and improving the reliability and adaptability of the system.

[0017] Preferably, a power-off friction area is further provided on the outer peripheral wall of the adjusting disc, which is arranged in an alternating manner with the communication areas; the power-off friction area is provided with a third friction surface for removing oxides and dirt on the surface of the electrical contact block. Beneficial effects: By arranging the power-off friction area and the communication areas in an alternating manner and adding a third friction surface, the automatic switching of the power supply and cleaning functions is realized. This design can not only effectively remove oxides and dirt on the surface of the electrical contact block, extend the service life, but also improve the reliability of the electrical connection, ensuring the long-term stable operation of the system.

[0018] Preferably, the surface of the connecting contact head is wrapped with a conductive elastic layer; the conductive elastic layer is one of graphene composite materials, conductive polymer materials or metal elastic materials. Beneficial effects: By wrapping the conductive elastic layer on the surface of the connecting contact head and providing multiple material selection options, it not only ensures good contact performance but also provides flexibility in material selection. This design not only improves the conductive efficiency and connection reliability but also has good wear resistance, extending the service life of the device.

[0019] Preferably, it further includes: a protective baffle fixed to the connecting frame by bolts; through holes are provided on the protective baffle, and the through holes are arranged in a plum blossom pattern or fan-shaped openings. Beneficial effects: By setting the protective baffle and the reasonable design of the through holes, while providing good protection, it is also convenient for the heat dissipation and wiring operation of the device. The bolt fixing method is convenient for disassembly and maintenance, and the overall has good protection performance, improving the safety and maintainability of the device.

[0020] Compared with the prior art, the technical solution of the present invention has the following advantages:

[0021] The multi-power selective connection device provided by the present invention realizes the flexible switching and fault isolation of the battery pack through the mode adjustment structure, can automatically select the optimal connection mode according to the battery state to ensure the continuous and reliable power supply of the system; the provided fouling 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 reducing the contact resistance and improving the conductive efficiency; the modular and symmetric structure design, combined with the double disc structure and coaxial design, improves the accuracy and stability of the connection, making the structure compact and convenient for installation and maintenance; by extending the remote control mechanism to the front of the vehicle and setting the pulling rope and the guide wheel group, it is convenient for the driver to perform rapid mode switching operations, and the speed reduction transmission mechanism provides precise adjustment and control; setting the protective baffle and the sealing structure provides reliable environmental protection and has multiple safety protection functions such as reverse connection prevention and overcurrent protection; the key components are made of wear-resistant materials and are designed with multiple sealing protection measures to ensure the long-term reliable operation of the device; the overall structure design is reasonable, the manufacturing cost is controllable, it is applicable to various electric vehicles, and the parameters and configurations can be flexibly adjusted according to actual needs, having a wide range of application prospects. Through the organic combination of the above 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 progress. Description of the Drawings

[0022] To more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0023] Figure 1 It is a schematic structural diagram of the present invention when applied to an electric vehicle frame;

[0024] Figure 2 It is a schematic internal structural diagram of the switching device of the present invention cooperating with a battery pack;

[0025] Figure 3 For Figure 2 The partial enlarged view at position I in;

[0026] Figure 4 It is a schematic structural diagram of the mode adjustment structure of the present invention;

[0027] Figure 5 It is a schematic structural diagram of the scale deposit cleaning structure of the present invention installed on an operation installation part;

[0028] Figure 6 It is a schematic structural diagram of the scale deposit cleaning structure of the present invention;

[0029] Figure 7 It is a schematic structural diagram of the adjustment disc of the present invention connected to an electrical contact block.

[0030] Reference numerals: vehicle frame 10, main support pipe 11, side bracket group 12, installation position 121, installation box body 13, controller 14, rear shock absorber 15, connection bracket 16, main footrest 17, steering support frame 18, battery pack 21, external connection wire 22, connection frame 30, multi-power selective connection device 40, communication contact head 41, mode adjustment structure 42, scale deposit cleaning structure 43, operation installation disc 44, adjustment disc 421, gear position contact combination 422, contact 4221, contact friction arc section 431, first friction surface 4311, connection through hole 4312, contact friction arc section 432, second friction surface 4321, installation disc 441, connection through hole 4411, arc groove 4412, installation space 442, protruding connection block 443, pulling rope 444, protective baffle 45, adjustment gear 51, gear transmission rod 52, relief notch 53, electrical connection wire 61, electrical contact block 62, elastic member 63, communication area 71, power-off friction area 72, third friction surface 721, placement housing 80, arc notch 81, electrical transmission wire 90. Detailed implementation manners

[0031] The following will combine Figures 1-7A preferred embodiment of the present invention will be described in detail. It should be noted that the following description is only a preferred embodiment of the present invention and does not limit 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 protection scope of the present invention shall be subject to the appended claims.

[0032] Embodiment 1:

[0033] Reference Figure 1 , this embodiment provides a multi-power selective connection device 40 for an electric vehicle and a battery monitoring system. The device is fixed below the main support pipe 11 of the vehicle frame through a specific mounting bracket. The multi-power selective connection device 40 is installed in the vehicle frame 10 of a two-wheeled electric vehicle. The vehicle frame 10 is connected to the steering support frame 18. The vehicle frame 10 includes a main support pipe 11 connected to the steering support frame 18. Multiple groups of symmetric side bracket groups 12 are connected to both sides of the main support pipe 11 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 pipe is 30 - 40 mm, and the diameter of the secondary support pipe is 20 - 25 mm. Each bracket group is fixedly connected by welding, and stiffening plates are added at key nodes. Multiple groups of side bracket groups 12 are arranged in a three-sided surrounding shape and form a mounting position 121 for placing the battery. An installation box body 13 with a waterproof design is arranged in the mounting position 121. The installation box body 13 has drainage holes and a ventilation structure, and a shock pad is arranged inside. The battery is installed in the installation box body 13.

[0034] Reference Figures 1-3 , the battery system consists of four 12V batteries, arranged in a square shape, and the four batteries are divided into two battery groups 21 with the symmetry axis consistent with the traveling direction of the electric vehicle as the boundary. The distance between the two battery groups 21 is 30 - 50 mm, forming a space for air circulation and device installation. This interval design has a dual function: on the one hand, it improves the battery heat dissipation effect through forced convection; on the other hand, it reserves space for installing the multi-power selective connection device 40. The multi-power selective connection device 40 is placed at the central position between the two battery groups 21 and is firmly connected to the electric vehicle frame 10 through the connecting frame 30 on its upper part. Each battery is equipped with an external connecting wire 22 of a standard specification. A waterproof electrical connector is arranged at the end of the external connecting wire 22. This electrical connector adopts a quick plug-and-play design and can be reliably separated and connected to the multi-power selective connection device 40.

[0035] Reference Figures 2-4 , the multi-power selective connection device 40 mainly consists of four groups of communicating contact heads 41, a mode adjustment structure 42, a scale deposit cleaning structure 43, and an operation mounting plate 44. Its structural features are as follows:

[0036] 1. Connected contact head layout: Each group of connected contact heads 41 and the dirt accumulation layer cleaning structure 43 are symmetrically arranged on both sides of the mode adjustment structure 42. The material of each group of connected contact heads 41 is gold-plated copper alloy. The four connected contact heads 41 on each side include two positive electrodes and two negative electrodes, and their contact area is not less than 12 mm².

[0037] 2. Electrode connection: Each positive or negative electrode is reliably connected to the corresponding battery electrode through the waterproof electrical connector of the external connecting wire 22, and the contact resistance is not greater than 0.5 mΩ.

[0038] 3. Motion mechanism: The mode adjustment structure 42 and the dirt accumulation layer cleaning structures 43 on both sides are connected by coaxial self-rotation, and the rotation torque is not greater than 0.8 N•m.

[0039] 4. Spatial layout: The four connected contact heads 41 on each side are distributed in an equally divided circular arc shape.

[0040] The number of groups of the connected contact heads 41 of the device can be flexibly configured according to the actual number of batteries and is symmetrically distributed on both sides of the mode adjustment structure 42.

[0041] The mode adjustment structure 42 includes the following key components:

[0042] 1. Adjustment disk 421: It is made of wear-resistant engineering plastic, and the dimensions are, for example, a diameter of 80 - 100 mm and a thickness of 15 - 20 mm.

[0043] 2. Contact point distribution: A plurality of contact points 4221 are equally spaced along the circumferential direction at both ends of the adjustment disk 421 (only the contact points at one end of the adjustment disk are shown in the figure). The contact points are made of silver-plated copper alloy, and the contact resistance is not greater than 0.3 mΩ.

[0044] 3. Gear combination: A plurality of contact points 4221 form several groups of gear contact point combinations 422. The contact points 4221 of each group of gear contact point combinations 422 are symmetrically distributed at both ends of the adjustment disk 421. The number of contact points in each group matches the number of connected contact heads 41, and reliable separation and contact can be achieved.

[0045] 4. Circuit design: Each gear contact point combination 422 corresponds to a different battery series connection state, and different mode circuit connections are realized through the wires (cross-sectional area not less than 2.5 mm²) inside the adjustment disk 421. The contact points 4221 can be reused in different gear contact point combinations 422 to improve space utilization. (The circuit connection is not shown in the figure).

[0046] By setting up a mode adjustment structure, when an abnormality occurs in one of the four batteries (voltage lower than 10.5V or current fluctuation exceeding ±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 41 contact and conduct with the qualified gear contact combination 422, realizing the reconnection 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 contacts is maintained within the range of 0.6 - 0.8 MPa.

[0047] Reference Figure 3 、 Figures 5-6 The scale deposit cleaning structure 43 includes: two contact friction arc segments 431 installed on both sides of the operation mounting disc 44 for cleaning the scale deposits on the two connecting contacts 41, and two contact point friction arc segments 432 for cleaning the scale deposits on the two ends of the contact points 4221. Among them, the two contact friction arc segments 431 and the two contact point friction arc segments 432 are both symmetric about both sides of the adjustment disc 421, and are both located between the adjustment disc 421 and the connecting contact 41 on their respective corresponding sides, maintaining a working gap. The contact friction arc segment 431 is made of a high-hardness material, such as tungsten carbide material (hardness not lower than HRA90), and is provided with four through holes 4312 through which the four connecting contacts 41 can pass one by one. The contact friction arc segment 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 segment 432 is provided with a second friction surface 4321 (adopting the same surface treatment process) that contacts the contact point 4221. All friction contact surfaces are subjected to anti-oxidation treatment, and the service life is not less than 10,000 reciprocating motions.

[0048] In this solution, by rotating the operation mounting disc 44, relative motion friction is generated between the two first friction surfaces 4311 on the two contact friction arc segments 431 and the connecting contact 41; by rotating the adjustment disc 421, the second friction surface 4321 on the two contact point friction arc segments 432 is used to clean the contact points 4221 at both ends of the adjustment disc 421 by friction. This design effectively solves the problem of scale deposits generated on the connecting contact 41 and the contact points 4221 due to factors such as environmental oxidation and electric spark corrosion during frequent switching. Through automatic cleaning during switching or regular friction cleaning, the surface roughness of the contacts can be maintained below Ra 1.6μm, and the contact resistance can be controlled within 0.5 mΩ, effectively ensuring the electrical conductivity between the connecting contact 41 and the contact points 4221. This active cleaning mechanism can avoid the increase in contact resistance caused by the thickening of the scale deposit 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%).

[0049] Further, a retention space is designed in the remaining space of the contact friction arc segment 431 except for the connection through-hole 4312, and this space can completely accommodate a connection contact head 41. This design endows the adjustment disc 421 with dual functions: on the one hand, it removes dirt through surface friction (frictional force 3 - 5 N); on the other hand, through stepwise rotation, the adjustment disc 421 can be accurately positioned so that each connection contact head 41 is completely within the space, thereby reliably isolating the contact between the connection contact head 41 and the contact point 4221 (insulation resistance > 100 MΩ). This isolation mechanism ensures that the battery can be in a completely disconnected state with a leakage current less than 1 mA, providing safety guarantees for system maintenance and battery replacement. The rotational positioning can adopt a ratchet structure with a self-locking function and a positioning accuracy of ±0.5°, preventing accidental contact.

[0050] Further, the inner wall of the connection through-hole 4312 is provided with a 15° chamfer (chamfer depth 0.5 - 0.8 mm) and its surface is anodized to ensure wear resistance. One end of the connection contact head 41 close to the contact point 4221 is designed as a spherical shape and plated with a 3 - 5 μm 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 through-hole 4312 is controlled between 0.1 - 0.15, and the operating force does not exceed 5 N, ensuring a smooth and reliable conversion process.

[0051] Furthermore, the surface of the connection contact head 41 is wrapped with a conductive elastic layer (thickness 0.2 - 0.3 mm), and the following materials can be selected for this conductive elastic layer:

[0052] 1. Graphene composite material: volume resistivity ≤ 10^-3 Ω·cm, elastic strain 20 - 30%

[0053] 2. Conductive polymer material: such as doped PEDOT:PSS, conductivity > 1000 S / cm

[0054] 3. Metal elastic material: such as beryllium copper alloy, yield strength ≥ 500 MPa

[0055] In this embodiment, a graphene composite material is adopted, which is composed of multiple layers of graphene (number of layers 8 - 12) and an elastomer (silicone rubber), and has excellent conductivity (lateral conductivity > 5000 S / cm) and mechanical properties. After the connection contact head 41 slides into the connection through-hole 4312, the conductive elastic layer generates an elastic pressure of 2 - 3 N to ensure a stable contact with the contact point 4221 (contact resistance < 0.3 mΩ), thereby realizing reliable power transmission (allowing instantaneous current ≥ 100 A).

[0056] To make the installation of the mode adjustment structure 42 and the dirt layer cleaning structure 43 compact, refer to Figures 2-3, the operation installation disk 44 adopts a symmetric design and includes two installation disks 441 formed by precision injection molding. A cylindrical installation space 442 (for example, with a diameter of 82 - 85 mm and an axial clearance of 0.2 - 0.3 mm) for installing the adjustment disk 421 is formed between the two installation disks 441. An annular sealing groove (for example, with a depth of 1.5 mm and a width of 2 mm) is provided on the inner wall of the space for installing a sealing ring. The two installation disks 441 are precisely machined with connection through holes 4411 (hole diameter tolerance H7) having a coaxiality error of less than 0.05 mm with the four connection through holes 4312.

[0057] The contact friction arc segment 431 and the contact point friction arc segment 432 are installed in the same installation disk 441 by means of a positioning pin (Φ3h6) and a pressing plate. 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 a dust and waterproof protection (protection level IP54) for the contact point 4221 on the adjustment disk 421 through a lip-shaped sealing ring, effectively avoiding the deposition of environmental pollutants (particle size > 10 μm) on the surface of the contact point 4221; on the other hand, by single-point driving the operation installation disk 44 (torque 1.2 - 1.5 N·m), 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, and with the cooperation of the ratchet positioning mechanism, the cleaning operation of the dirt accumulation layer is more efficient and reliable.

[0058] Furthermore, the installation disk 441 is provided with an arc groove 4412 (groove depth 4 - 5 mm, arc radius 35 - 40 mm, groove width matching the thickness of the friction disk, and clearance 0.05 - 0.1 mm). Both the contact friction arc segment 431 and the contact point friction arc segment 432 adopt precisely machined arc shapes (arc span 120°, thickness 3 ± 0.02 mm) and are precisely installed in the arc groove 4412 through positioning bosses (height 2 mm). Among them, the contact point friction arc segment 432 passes through the arc groove 4412 through a precisely machined through hole (hole diameter tolerance H7) and maintains a working clearance of 0.2 - 0.3 mm with the contact point 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 not exceeding 12 mm), ensuring that the overall layout dimensions of the battery and the multi-power selective connection device 40 are controlled within the range of 100×80×40 mm.

[0059] For the convenience of rotating the adjustment disk 421, refer to Figures 2-4, on one circular end face edge of the adjusting disc 421, a complete circumferential adjusting gear 51 is integrally machined (parameters can be: module 1.5, number of teeth 40, pressure angle 20°, tooth width 8 mm), and the adjusting gear 51 adopts a precision carburizing and quenching process (surface hardness HRC58 - 62). This gear forms a speed reduction drive (transmission ratio 2:1) with a gear transmission rod 52 made of 20CrMnTi (parameters can be: module 1.5, number of teeth 20), and the side clearance of the gear pair is controlled within 0.1 - 0.15 mm. 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 end play ≤ 0.5 mm) and extends to the front part of the vehicle head, and is connected to the adjusting operation component at the vehicle head by a spline connection (SAE spline, 6 teeth).

[0060] When adjusting the battery connection mode, the operator drives the gear transmission rod 52 to rotate through the adjusting operation component at the vehicle head (operation torque requirement ≤ 2 N·m), and the transmission mechanism amplifies the torque and drives the adjusting disc 421 to perform precise positioning rotation (indexing accuracy ±1°), realizing a reliable switch of the battery connection mode. The drive for the adjusting disc 421 can be any one in the prior art.

[0061] Furthermore, the diameter of the mounting disc 441 is designed to be larger than that of the adjusting disc 421, and a 45° sector-shaped relief notch 53 (depth matching the gear module) is designed on the mounting disc 441 near the adjusting gear 51. A sealing lip (made of nitrile rubber, thickness 1 mm) is arranged at the edge of the notch, which can provide a dust-proof effect while ensuring gear meshing.

[0062] The above design forms an IP54-level protection for the adjusting disc 421 through the mounting disc 441. Combining the precise design of the relief notch 53, it not only ensures the reliable meshing drive (contact ratio coefficient 1.2 - 1.4) between the adjusting gear 51 and the gear transmission rod 52, but also minimizes the possibility of dust entry (sealing ring compression rate 15 - 20%). The service life of the entire transmission system is not less than 10,000 switching cycles.

[0063] For the convenience of rotating the mounting disc 44, refer to Figures 2-3 , the operating mounting disc 44 further includes protruding connecting blocks 443 (made of aluminum alloy 6061 - T6, surface anodized treatment) connected by high-strength bolts (strength grade 8.8) at the edges of the two mounting discs 441. The protruding connecting blocks 443 are provided with positioning grooves (depth 3 mm, fillet R1) for fixing the steel wire rope. The protruding connecting blocks 443 are connected with a high-strength pulling rope 444 through a special ferrule, and the pulling rope 444 is reliably connected to the starting operation component at the front part of the vehicle head after being guided by a guide wheel set (using sealed bearings 6000 - 2RS).

[0064] To achieve the power supply of the battery to the electric vehicle, refer to Figures 2-4 , Figure 7 , there are communication areas 71 evenly distributed at intervals of 45° along the circumferential direction on the outer peripheral wall of the adjusting disc 421. The communication areas 71 are made of composite conductive materials, and the following solutions can be selected:

[0065] 1. Metal material: gold-plated copper alloy, conductivity ≥ 90% IACS

[0066] 2. Semiconductor material: doped silicon-based material, resistivity ≤ 0.01 Ω·cm

[0067] 3. Carbon-based material: graphene composite material, surface resistance < 0.1 Ω

[0068] In this embodiment, gold-plated copper alloy (purity ≥ 99.9%, coating thickness 3 - 5μm) is adopted. There are two groups of electrical connection devices on the outer peripheral wall of the adjusting disc 421, such as electrical connection wires 61 with a specification of 16mm² and electrical contact blocks 62 made of silver-plated copper alloy (purity ≥ 99.9%). One group 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°C), and the other group of connection devices is led to low-power devices such as the LCD display screen (power consumption ≤ 2W) at the front of the vehicle.

[0069] This setting can achieve reliable contact (contact resistance ≤ 0.2mΩ) or disconnection between the communication area 71 and the electrical contact block 62 by precisely rotating the adjusting disc 421 (angle error ≤ ±1°). When temporary power-off is required, align the non-conductive area with the electrical contact block 62, which can effectively reduce the standby power consumption (≤ 0.1W).

[0070] Furthermore, a power-off friction area 72 is also provided on the outer peripheral wall of the adjusting disc 421, which is arranged in an alternating manner with the communication area 71 (spacing 22.5°). The power-off friction area 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 micro-grooves (depth 0.1mm, spacing 0.5mm), which can effectively remove the oxides and scale (thickness ≤ 0.05mm) on the surface of the electrical contact block 62.

[0071] To ensure the contact reliability, the electrical contact block 62 is flexibly connected to the electrical connection wire 61 through an elastic member 63 (elastic coefficient 10N / mm) with gold plating treatment (thickness 2 - 3μm). The elastic member 63 provides a contact pressure of 2 - 3N to ensure the stability of the contact resistance.

[0072] All electrical connection wires 61 are routed in zones and installed in a placement housing 80 with a flame retardant rating of V0. The arc-shaped notch 81 (arc radius 42 mm) of the placement housing 80 is in interference fit (interference amount 0.1 - 0.2 mm) with the mounting disc 441 to achieve IP54 protection. At the same time, the electrical transmission wire 90 (cross-sectional area 2.5 mm²) of the monitoring system also adopts the same protection scheme.

[0073] To protect the core functional components, a protective baffle 45 with a thickness of 2 mm (PC / ABS material, flame retardant rating V0) is designed, which can be fixed to the connecting frame 30 by 4 M4 bolts. The through holes on the baffle are arranged in a plum blossom pattern (hole diameter 12 mm, pitch 30 mm) or 120° sector-shaped openings (radius 25 mm) to ensure the convenience of wiring.

[0074] The working principle of switching the power supply battery and cleaning the scale layer in this embodiment:

[0075] First, operate the start operation component at the front of the vehicle. By pulling the pulling rope 444 (stroke 15 - 20 mm), drive the two mounting discs 441 to rotate synchronously. This action makes the connecting contact head 41 slide precisely into the corresponding connection through hole 4312 and the connecting through hole 4411 at a speed of 0.2 - 0.3 m / s (positioning accuracy ≤ 0.1 mm), achieving reliable contact between the connecting contact head 41 and the contact point 4221 (contact pressure 0.6 - 0.8 MPa). At this time, the monitoring system real-time collects the working states of the four batteries through a high-precision voltage sensor (resolution ±0.01 V) and a current sensor (range 0 - 100 A, accuracy 0.5%). Based on the collected data, the system selects the optimal battery connection mode. Subsequently, drive the gear transmission rod 52 to rotate (rotation speed 60 - 120 rpm) by operating the adjustment operation component at the front of the vehicle (maximum operating torque 2 N·m), driving the adjustment disc 421 to rotate precisely to the target position (positioning accuracy ±1°), so that the appropriate gear contact point combination 422 forms a stable contact with the connecting contact head 41 (contact resistance ≤ 0.3 mΩ).

[0076] 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°C to 60°C, internal resistance 5 - 15mΩ). When abnormal conditions such as the battery voltage being lower than 10.5V, the temperature exceeding 55°C, the discharge current exceeding 45A, or the internal resistance mutating by more than 30% are detected, protection is triggered; when the pulling rope 444 is pulled, through a precision transmission mechanism (backlash ≤ 0.1mm), the two mounting disks 441 are driven to rotate synchronously. The rotation of the mounting disk 441 drives the integrally mounted contact friction arc segment 431 to move together, and the surface of the connecting contact head 41 is cleaned under a pressure of 0.6 - 0.8MPa. This active cleaning mechanism can remove the scale caused by oxidation and spark corrosion (the thickness is usually 0.02 - 0.05mm), keep the contact resistance below 0.5mΩ all the time, and ensure a stable power transmission efficiency (≥99.5%) and the service life of the equipment.

[0077] The design of the gear contact combination working modes includes the normal working mode (48V, four batteries in series, T1 - T2 connect battery 1, T3 - T4 connect battery 2, T5 - T6 connect battery 3, T7 - T8 connect battery 4, the working voltage 48V is 12V × 4), emergency mode 1 (36V, three batteries in series, that is, the faulty battery is skipped, T1 - T2 connect battery 1, T3 - T4 connect battery 2, T5 - T6 connect battery 3, T7 - T8 are disconnected, the working voltage 36V is 12V × 3), emergency mode 2 (24V, two batteries in series, T1 - T2 connect battery 1, T3 - T4 connect battery 2, T5 - T8 are all disconnected, the working voltage 24V is 12V × 2), and the diagnostic mode (detect the state of each battery separately, any battery can be connected separately, used for battery performance detection and maintenance); the special design considerations include that each group of contacts has a polarity mark, an anti-reverse connection protection mechanism is provided, there is enough safety distance between contacts to prevent short circuit, and the cleaning structure can cover all contact positions; the switching mechanism design uses a one-way rotation of the adjusting disk to avoid poor contact, there is an overlapping area during the contact transition to ensure continuous power supply, and the gears have clear marks and positioning structures.

[0078] It should be noted that all specific parameters involved in the present invention are preferred implementation manners and not the only limiting values. For example, the voltage value of the battery can be selected with other specifications according to actual requirements, and the connection method can also be flexibly adjusted according to the actual usage scenario; the safe distance between the contacts can be appropriately adjusted according to the actual working voltage level, but it should be ensured to comply 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 usage environment; the reduction ratio and operating torque of the transmission mechanism can be optimized according to the requirements of actual operation convenience; the sampling frequency and accuracy of the monitoring system can be adjusted according to the requirements of specific application scenarios. The specific parameters and design schemes in this embodiment are mainly optimized based on the usage environment and performance requirements of two-wheeled electric vehicles. On the premise of ensuring safety and reliability, the 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; An operating mounting plate for mounting the adjusting disc and the fouling layer cleaning structure; 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; 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; 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.

2. 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.

3. The multi-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.

4. 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.

5. The multiple power selective connection device for electric vehicles according to claim 4, 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.

6. The multiple power selective connection device for electric vehicles according to claim 1, 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.

7. 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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