Battery replacement locking safety control method
By using the locking mechanism to decompose the locking process in the bottom-changing of heavy trucks and making logical judgments based on the torque change, the deformation of the battery swap frame due to the vehicle's bending and torsional working conditions is solved, and the safety and reliability of the locking process are achieved.
Patent Information
- Application Number
- CN202510383768.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-28
- Publication Date
- 2025-05-23
AI Technical Summary
During the bottom-type battery replacement of heavy trucks, the battery replacement frame is easily deformed due to the bending and torsion of the vehicle, resulting in uneven stress at the mounting point and fatigue failure is prone to problems.
A safety control method for battery swap lock is adopted. The locking process is divided into three processes: suspended propulsion, climbing and platform propulsion through the locking mechanism. Combined with the locking tongue stroke parameters, pad compression variables and locking motor torque changes, logical judgment is made to identify abnormal situations in the locking process.
Effectively identify and prevent foreign objects, improper locking and overloading of the locking tongue, ensure the safety and reliability of the locking process, prevent deformation of the battery swap frame and fatigue failure of the mounting point.
Smart Images
Figure CN120024190A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of vehicle battery replacement technology, and more specifically to a battery replacement lock safety control method. Background Art
[0002] The electrification of heavy-duty trucks is an inevitable trend to solve the international energy crisis and achieve the "dual carbon" goal. The heavy-duty truck battery replacement mode has become an important way to promote the penetration rate of electric heavy-duty trucks due to its advantages such as rapid energy replenishment, high economy, and battery friendliness.
[0003] At present, heavy-duty truck battery swapping can be divided into top-hanging, bottom-swapping and side-swapping according to the battery swapping method. Among them, bottom-swapping has become the preferred choice for electrification in trunk logistics scenarios due to its advantages of low center of gravity, high handling stability, large battery capacity and long endurance. In the bottom-swapping method, the battery swapping frame is mounted at the bottom of the frame beam, so the battery swapping frame needs to withstand the bending and torsion conditions of the vehicle, which makes the battery swapping frame prone to deformation, and then makes the mounting points on the battery swapping frame unevenly stressed, and prone to fatigue failure. In the existing mainstream technology, the mounting point of the battery swapping is the locking mechanism on the battery swapping frame. Therefore, it is extremely important for the reliable operation of the vehicle to identify the deformation of the mounting point of the battery swapping frame during the battery swapping process and stop the battery swapping in time. Summary of the invention
[0004] The purpose of the present invention is to provide a battery replacement lock safety control method to solve the above-mentioned problem.
[0005] The present invention adopts the following technical solution: A battery swap lock safety control method includes a battery swap lock mechanism, the battery swap lock mechanism includes an upper frame, a lower frame, a padlock, a locking roller, a locking tongue, a locking motor, a cushion and a lifting platform, the upper frame is installed on a vehicle frame, the locking tongue and the locking motor are installed on the vehicle frame or the upper frame, the lower frame is used to load a power battery, the cushion is arranged between the upper frame and the lower frame, the lifting platform is used to lift the lower frame close to the upper frame to complete the battery swap during battery swap, the padlock is fixedly installed on the top surface of the lower frame, the padlock is provided with a lock hole, the locking roller is arranged in the lock hole, the upper frame is provided with a lock opening matched with the padlock, the padlock passes through the lock opening of the upper frame, and is locked by the lock tongue inserted into the lock hole, the locking motor is connected to the lock tongue through a push rod, and pushes the lock tongue forward to extend into or backward to exit the lock hole, and the front end of the lock tongue is provided with a wedge-shaped inclined surface.
[0006] The safety control method of the battery replacement locking mechanism includes the following steps: S1. The locking process of inserting the lock tongue into the lock hole is divided into a suspended advancement process, a climbing process and a platform advancement process. The distance completed by the lock tongue during the suspended advancement process is X. 1 , the travel of the lock tongue during the climbing process is X 2; and the torque changes of the locking motor in each locking process under various working conditions are measured through experiments, among which, the torque changes of the locking motor in the expected locking process are measured through benchmark tests, and the baseline line L1 of the torque change in each locking process is obtained; through simulation tests, the locking motor torque change line L2 is measured during the climbing process when the soft pad is in contact with the upper frame and is in a state of zero compression; through simulation tests, the locking motor torque change line L3 is measured during the climbing process when the soft pad is in contact with the upper frame and is at the critical point of pre-tightening interference.
[0007] S2, the locking process begins, the lock tongue enters the suspended advancement process, and it is determined that during this process, the torque of the locking motor is within the travel X d Does the internal torque exceed T? 1 +△T, if it exceeds, it will identify the possible presence of foreign objects, issue an alarm, and switch to unlocking action, requiring manual clearance before re-locking. If it does not exceed, execute step S3; where X d =X 1 -△X, △X is the reference travel of the cushion under the pre-tightening and compression deformation when the upper frame and the lower frame are tightly fitted and pre-advanced; T 1 is the torque value of the baseline L1 in the suspended propulsion area, and △T is the set safety boundary value.
[0008] S3, determine whether it has entered the climbing process, that is, whether the lock tongue travel exceeds X d If yes, execute step S4, otherwise execute step S2.
[0009] S4, determine whether the torque of the locking motor is less than T during the climbing process 2 If yes, then execute step S5; otherwise, identify that the lifting platform is abnormal and the preload force is insufficient, issue an alarm, stop the locking process, and wait for the lifting platform to be adjusted to the right position and then test again. If multiple tests still fail, then turn to unlocking and re-lock after manual inspection; where T 2 It is the torque value at the starting point of the climbing of the change line L2.
[0010] S5. Determine whether the torque of the locking motor exceeds T during the climbing process 3 If yes, it is identified as a lock tongue overload, an alarm is issued, the locking process is stopped, and manual inspection is required before re-locking, otherwise step S6 is executed; wherein, T 3 It is the moment value when the cushion is compressed to the effective compression amount.
[0011] S6: Determine whether the platform has entered the advancement process, that is, whether the travel exceeds X 2 If yes, execute step S7, otherwise execute step S5.
[0012] S7, determine whether the locking motor torque is lower than T 4If yes, it is identified as unreliable locking, an alarm is issued, and the locking process is stopped. It is necessary to manually check whether to continue the locking process, otherwise, step S8 is executed; wherein, T 4 It is the minimum locking torque value during the platform propulsion process.
[0013] S8, judging whether the locking is in place, if the locking is in place, completing the locking process, if the locking is not in place, continuing to execute step S7.
[0014] Further, in step S1, the suspended propulsion process is the process from when the locking motor just starts to propel the lock tongue to when the locking roller just contacts the wedge-shaped inclined surface of the lock tongue, the climbing process is the process from when the locking roller just contacts the wedge-shaped inclined surface of the lock tongue to when the locking roller just contacts the upper plane of the lock tongue, and the platform propulsion process is the process of the locking roller propulsion on the upper plane of the lock tongue.
[0015] Furthermore, the step S1 also includes a change line L4 of the upper limit value of the locking motor torque corresponding to the soft cushion compression amount not being within the preset range caused by the deformation of the upper and lower frames measured through simulation tests, and includes a change line L5 of the lower limit value of the locking motor torque corresponding to the soft cushion compression amount not being within the preset range caused by the deformation of the upper and lower frames measured through simulation tests.
[0016] Preferably, in step S1, the enclosed area formed by the change line L2 to the change line L5 is a torque safety threshold area for locking the motor during the climbing process and the platform propulsion process.
[0017] Furthermore, in step S2, the thickness of the cushion is a, the maximum compression of the cushion is b, the preload reference compression is c, the effective compression is d, c<d<b, the wedge angle of the lock tongue is α, △X=c*cot(α), and cot is the cotangent function.
[0018] Furthermore, in step S4, the lifting platform is adjusted to be re-tested three times, and an alarm is sent if the three tests fail.
[0019] Furthermore, in step S8, the locking motor is equipped with a locking limit sensor, and the locking limit sensor is used to sense and determine whether the locking is in place.
[0020] From the above description of the structure of the present invention, it can be seen that compared with the prior art, the present invention has the following advantages: 1. The present invention divides the locking process into three processes according to the mechanical structure characteristics, and respectively targets the torque characteristics of the locking motor in the three processes, combines the lock tongue stroke parameters and the cushion compression variables, and uses the logical judgment of steps S2 to S8 to identify whether there are foreign objects in the locking process, whether the locking is in place, whether the lock tongue is effectively and reliably loaded, whether the RGV posture and preload are normal, etc., and then identifies whether the battery replacement frame shape variables exceed the limit, and promptly reminds inspection and maintenance to ensure that related components are not damaged due to excessive thrust, while ensuring the driving safety of the vehicle.
[0021] 2. During the three locking processes of the present invention, when calculating the torque change of the locking motor, the reference stroke of the pre-tightening compression deformation of the soft pad is introduced to calculate the stroke parameters, so that the torque change and stroke comparison results of the locking motor are more accurate and reliable, and also provide a reliable comparison variable for the posture of the lifting platform.
[0022] 3. The present invention measures the torque baseline L1 and change lines L2-L5 of the locking motor through benchmark tests and simulation tests under various working conditions, and obtains the torque safety threshold area of the locking motor during the climbing process and platform propulsion process through the enclosed area formed by the change lines L2-L5, providing an objective, accurate, true and reliable calculation basis for the safety control method. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Figure 1 It is a structural schematic diagram of the power replacement locking mechanism of the present invention.
[0024] Figure 2 It is a schematic diagram of the change of the locking motor torque during the locking process of the present invention.
[0025] Figure 3 It is a control flow chart of the present invention.
[0026] in, Figure 1 The middle numbers are: upper frame 10, lower frame 20, padlock 30, locking roller 40, lock tongue 50, locking motor 60, cushion 70, lifting platform 80; Figure 2 The X axis is the forward travel of the lock tongue, the T axis is the torque of the locking motor, and X1 is the travel X of the lock tongue during the suspended propulsion process. 1 , X1 is the travel distance of the lock tongue during the climbing process 2 , △X1 represents the difference between the lower limit stroke of the preload force provided by the lifting platform RGV and the reference stroke, and △X2 represents the difference between the upper limit stroke of the preload force provided by the lifting platform RGV and the reference stroke. DETAILED DESCRIPTION
[0027] The specific implementation of the embodiment of the present invention is described below with reference to the accompanying drawings.
[0028] Reference Figure 1, a battery replacement lock safety control method is applied to the battery replacement operation of electric vehicles. As a preferred embodiment, the present embodiment takes the chassis battery replacement method as an example. Among them, it includes a battery replacement locking mechanism, which includes an upper frame, a lower frame, a padlock, a locking roller, a lock tongue, a locking motor, a cushion and a lifting platform. The upper frame is installed on the frame, and the lock tongue and the locking motor are installed on the frame or the upper frame. The lower frame is used to load the power battery, and the cushion is arranged between the upper frame and the lower frame. The lifting platform is used to lift the lower frame close to the upper frame to complete the battery replacement when replacing the battery. In this embodiment, the lifting platform is preferably an RGV device. The padlock is fixedly installed on the top surface of the lower frame, and a lock hole is provided on the padlock, and a locking roller is provided in the lock hole. The upper frame is provided with a lock port that matches the padlock. The padlock passes through the lock port of the upper frame and is locked by the lock tongue inserted into the lock hole. The locking motor is connected to the lock tongue through a push rod, and the lock tongue is pushed forward to extend into or backward to exit the lock hole. The front end of the lock tongue is provided with a wedge-shaped inclined surface.
[0029] The battery-swap locking mechanism of the present invention is a prior art, so only a brief overview is given here, and its specific structure and working principle are not further elaborated. In addition, the battery-swap locking mechanism is a mounting point for the upper and lower frames, and the number of the mounting points is usually multiple and spaced apart. This embodiment uses a single battery-swap locking mechanism as the basis for development, but in actual applications, each battery-swap locking mechanism should make the same safety control.
[0030] Reference Figures 1 to 3 , the safety control method of the battery replacement locking mechanism includes the following steps: S1. The locking process of inserting the lock tongue into the lock hole is divided into a suspended advancement process, a climbing process and a platform advancement process. Figure 1 , the travel of the lock tongue during the suspended advancement process is X 1 , the travel of the lock tongue during the climbing process is X 2 The suspended advancement process is the process from when the locking motor just starts to advance the lock tongue to when the locking roller just contacts the wedge-shaped inclined surface of the lock tongue. The climbing process is the process from when the locking roller just contacts the wedge-shaped inclined surface of the lock tongue to when the locking roller just contacts the upper plane of the lock tongue. The platform advancement process is the process of the locking roller advancing on the upper plane of the lock tongue.
[0031] Reference Figure 2, the torque changes of the locking motor in each locking process under various working conditions are measured through experiments. Among them, the torque changes of the locking motor in the expected locking process are measured through benchmark tests, and the baseline line L1 of the torque changes in each locking process is obtained. Through simulation tests, the change line L2 of the locking motor torque during the climbing process when the soft pad is in contact with the upper frame and in a state of zero compression is measured. Through simulation tests, the change line L3 of the locking motor torque during the climbing process when the soft pad is in contact with the upper frame and is at the critical point of pre-tightening interference is measured. Through simulation tests, the change line L4 of the upper limit value of the locking motor torque corresponding to the compression of the soft pad not being within the preset range caused by the deformation of the upper and lower frames is measured. Through simulation tests, the change line L5 of the lower limit value of the locking motor torque corresponding to the compression of the soft pad not being within the preset range caused by the deformation of the upper and lower frames is measured.
[0032] Reference Figure 2 The enclosed area formed by the change line L2 to the change line L5 in the figure is the torque safety threshold area for locking the motor during the climbing process and the platform propulsion process. The torque safety threshold area is an important indicator for the subsequent setting and calculation of the torque threshold parameter.
[0033] S2, the locking process begins, the lock tongue enters the suspended advancement process, and it is determined that during this process, the torque of the locking motor is within the travel X d Does the internal torque exceed T? 1 +△T, if it exceeds, it will identify the possible presence of foreign objects, issue an alarm, and switch to unlocking action, requiring manual clearance before re-locking. If it does not exceed, execute step S3; where X d =X 1 -△X, △X is the reference travel of the cushion under the pre-tightening and compression deformation when the upper frame and the lower frame are tightly fitted and pre-advanced; T 1 is the torque value of the baseline L1 in the suspended propulsion area, and △T is the set safety boundary value.
[0034] More specifically, the thickness of the cushion is a, the maximum compression of the cushion is b, the preload reference compression is c, the effective compression is d, c<d<b, the wedge angle of the lock tongue is α, △X=c*cot(α), cot is the cotangent function.
[0035] S3, determine whether it has entered the climbing process, that is, whether the lock tongue travel exceeds X d If yes, execute step S4, otherwise execute step S2.
[0036] S4, determine whether the torque of the locking motor is less than T during the climbing process 2 If yes, then execute step S5; otherwise, identify that the lifting platform is abnormal and the preload force is insufficient, issue an alarm, stop the locking process, and wait for the lifting platform to be adjusted to the right position before testing again. If multiple tests still fail, preferably three times in this embodiment, the system will turn to unlocking after three failures, and need to be manually checked before re-locking.2 It is the torque value at the starting point of climbing of the variation line L2, that is, the torque value at the starting point of climbing when the soft cushion is in contact with the upper frame and is in a state of zero compression.
[0037] S5. Determine whether the torque of the locking motor exceeds T during the climbing process 3 If yes, it is identified as a lock tongue overload, an alarm is issued, the locking process is stopped, and manual inspection is required before relocking. Otherwise, step S6 is executed. 3 It is the moment value when the cushion is compressed to the effective compression amount.
[0038] T 3 The torque value is obtained based on the torque safety threshold area formed by the change line L2 to the change line L5 in the above step S1, as well as product parameters, multiple tests, engineer experience, etc. During this step, it is possible to identify in advance whether the battery swap frame is deformed and whether the compression of the cushion exceeds the effective compression value, so as to prevent the motor from continuing to output and causing stalling, damaging components, or deformation and damage of the actuator due to excessive thrust.
[0039] S6: Determine whether the platform has entered the advancement process, that is, whether the travel exceeds X 2 If yes, execute step S7, otherwise execute step S5.
[0040] S7, determine whether the locking motor torque is lower than T 4 If yes, it is identified as unreliable locking, an alarm is issued, and the locking process is stopped. It is necessary to manually check whether to continue the locking process, otherwise, step S8 is executed; wherein, T 4 It is the minimum locking torque value during the platform propulsion process.
[0041] T 4 The torque value is based on the torque safety threshold area formed by the change line L2 to the change line L5 in the above step S1, as well as product parameters, multiple tests, engineer experience, etc. During this step, it can be ensured whether the load of the lock tongue meets the standard to ensure that other locks will not be overloaded (several locking mechanisms are provided on the battery swap frame to jointly carry the battery pack. If a locking mechanism is underloaded, the load will be distributed to other locking mechanisms, causing overload and damage to other locking mechanisms).
[0042] S8, judging whether the locking is in place, that is, judging by the built-in locking limit sensor of the locking motor, if the locking is in place, the locking process is completed, if the locking is not in place, then continue to execute S7. In this embodiment, the locking motor is preferably a locking motor with a built-in locking limit sensor.
[0043] The above is only a specific implementation of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial changes to the present invention using this concept shall be deemed as an infringement of the protection scope of the present invention.
Claims
1. A battery replacement locking safety control method, comprising a battery replacement locking mechanism, the battery replacement locking mechanism comprising an upper frame, a lower frame, a padlock, a locking roller, a lock tongue, a locking motor, a cushion and a lifting platform, the upper frame is installed on the vehicle frame, the lock tongue and the locking motor are installed on the vehicle frame or the upper frame, the lower frame is used to load the power battery, the cushion is arranged between the upper frame and the lower frame, and the lifting platform is used to lift the lower frame close to the upper frame to complete the battery replacement during battery replacement, the padlock is fixedly installed on the top surface of the lower frame, the padlock is provided with a lock hole, the lock roller is arranged in the lock hole, the upper frame is provided with a lock opening matched with the padlock, the padlock passes through the lock opening of the upper frame, and is locked by the lock tongue inserted into the lock hole, the locking motor is connected to the lock tongue through a push rod, and pushes the lock tongue forward to extend into or retreat out of the lock hole, and the front end of the lock tongue is provided with a wedge-shaped inclined surface, characterized in that: The safety control method of the battery replacement locking mechanism comprises the following steps: S1. The locking process of inserting the locking tongue into the lock hole is divided into a suspended propulsion process, a climbing process and a platform propulsion process. The travel completed by the locking tongue during the suspended propulsion process is X1, and the travel completed by the locking tongue during the climbing process is X2; and the torque change of the locking motor in each locking process under various working conditions is measured through experiments, wherein the torque change of the locking motor in the expected locking process is measured through a benchmark test, and the baseline line L1 of the torque change in each locking process is obtained; the change line L2 of the locking motor torque is measured during the climbing process when the soft pad is in contact with the upper frame and is in a state of zero compression through a simulation test; the change line L3 of the locking motor torque is measured during the climbing process when the soft pad is in contact with the upper frame and is in a pre-tightening interference critical point through a simulation test; S2, the locking process begins, the lock tongue enters the suspended advancement process, and it is determined that during this process, the torque of the locking motor is within the travel X d Whether the internal torque exceeds T1+△T, if it exceeds, it will identify the possible presence of foreign matter, issue an alarm, and switch to unlocking action, requiring manual clearance before re-locking, if it does not exceed, execute step S3; where X d = X1-△X, △X is the reference stroke of the cushion being pre-tightened and compressed when the upper frame and the lower frame are in close contact and pre-advanced state; T1 is the torque value of the reference line L1 in the suspended advancement area, and △T is the set safety boundary value; S3, determine whether it has entered the climbing process, that is, whether the lock tongue travel exceeds X d If yes, execute step S4, otherwise execute step S2; S4, determine whether the torque of the locking motor is less than T2 during the climbing process. If so, execute step S5; otherwise, identify that the lifting platform is in an abnormal posture and the preload force is insufficient, issue an alarm, stop the locking process, and wait for the lifting platform to be adjusted into place and then test again. If multiple tests still fail, unlock and re-lock after manual inspection; T2 is the torque value at the starting point of the climbing of the change line L2; S5, determine whether the torque of the locking motor exceeds T3 during the climbing process. If so, it is identified as a lock tongue overload, an alarm is issued, the locking process is stopped, and manual inspection is required before re-locking. Otherwise, execute step S6; wherein T3 is the torque value when the soft cushion is compressed to the effective compression amount; S6, determine whether the platform has entered the propulsion process, that is, whether the stroke exceeds X2, if so, execute step S7, otherwise execute step S5; S7, determine whether the locking motor torque is lower than T4, if so, identify it as unreliable locking, issue an alarm, stop the locking process, and need manual inspection to determine whether to continue the locking process, otherwise execute step S8; T4 is the minimum locking torque value of the platform propulsion process; S8, judging whether the locking is in place, if the locking is in place, completing the locking process, if the locking is not in place, continuing to execute step S7.
2. A battery replacement lock safety control method according to claim 1, characterized in that: In step S1, the suspended propulsion process is the process from when the locking motor just starts to propel the lock tongue to when the locking roller just contacts the wedge-shaped inclined surface of the lock tongue, the climbing process is the process from when the locking roller just contacts the wedge-shaped inclined surface of the lock tongue to when the locking roller just contacts the upper plane of the lock tongue, and the platform propulsion process is the process of the locking roller propulsion on the upper plane of the lock tongue.
3. A battery replacement lock safety control method according to claim 1, characterized in that: The step S1 also includes a change line L4 of the upper limit value of the locking motor torque corresponding to the cushion compression amount not being within the preset range due to the deformation of the upper and lower frames measured through simulation tests, and a change line L5 of the lower limit value of the locking motor torque corresponding to the cushion compression amount not being within the preset range due to the deformation of the upper and lower frames measured through simulation tests.
4. A battery replacement lock safety control method according to claim 3, characterized in that: In the step S1, the enclosed area formed by the change line L2 to the change line L5 is the torque safety threshold area for locking the motor during the climbing process and the platform propulsion process.
5. A battery replacement lock safety control method according to claim 1, characterized in that: In step S2, the thickness of the cushion is a, the maximum compression of the cushion is b, the preload reference compression is c, the effective compression is d, c<d<b, the wedge angle of the lock tongue is α, △X=c*cot(α), and cot is the cotangent function.
6. A battery replacement lock safety control method according to claim 1, characterized in that: In step S4, the lifting platform is adjusted to be re-tested three times, and an alarm is sent if the three tests fail.
7. A battery replacement lock safety control method according to claim 1, characterized in that: In step S8, the locking motor is equipped with a locking limit sensor, and the locking limit sensor is used to sense and judge whether the locking is in place.