Off-road pure electric wide-body vehicle and battery replacement method thereof

Abstract

The present invention discloses an off-road pure electric wide-body vehicle, which belongs to the field of battery replacement technology, including: a vehicle frame, a power system, a suspension system, a traveling system, a cargo box, a cab assembly, a battery assembly, and also includes: a top dead center sensor plate and a top dead center proximity switch, a bottom dead center sensor plate and a bottom dead center proximity switch, a battery replacement rocker switch for responding to a user's battery replacement instruction, a vehicle controller for sending a wireless connection instruction, an on-board battery replacement controller for starting a wireless communication module to establish a connection with a battery replacement station, wherein the vehicle controller determines whether the cargo box is lifted or lowered into place through the low level and high level output by the top dead center proximity switch and the bottom dead center proximity switch, and sends a judgment signal to the battery replacement station. The present invention also discloses a battery replacement method for an off-road pure electric wide-body vehicle. This method can accurately control the position of the cargo box, avoid the situation where the cargo box is lifted too high or not lowered into place, ensure the smooth progress of the battery replacement process, and improve the safety and efficiency of the battery replacement.

Description

Technical Field

[0001] The present invention relates to the field of battery replacement technology. More specifically, the present invention relates to an off-road pure electric wide-body vehicle and a battery replacement method thereof. Background Art

[0002] In today's mining transportation sector, fuel consumption accounts for a growing proportion of transportation costs, often reaching 60-70%, with some mining areas even experiencing a price-to-performance imbalance. Against this backdrop, pure electric wide-body dump trucks, with their near-zero energy consumption under heavy-load downhill conditions, are gaining widespread attention and are gradually gaining popularity in major mining areas.

[0003] However, pure electric wide-body dump trucks still face numerous challenges in practical application. When operating uphill with heavy loads, their power consumption is excessively high, requiring multiple recharges during a single shift. This not only causes significant inconvenience for customers but also makes it virtually impossible for the vehicle to meet its single-shift operating targets. Furthermore, the vehicle price is typically more than double that of a fuel-powered vehicle of the same tonnage, resulting in high purchase costs and a long payback period. To alleviate these issues, battery-swap off-highway dump trucks have been developed and implemented. Battery-swap technology is crucial for improving the efficiency and economical operation of these vehicles.

[0004] However, existing battery swapping methods for off-road pure electric wide-body vehicles suffer from numerous drawbacks. First, cargo box position detection is inaccurate. Traditional battery swapping processes lack reliable means for detecting cargo box position, making it difficult to accurately determine whether the cargo box is properly lifted and lowered. Lifting the cargo box too high could cause collisions with the roof of the battery swap station or other facilities, damaging the vehicle structure; failing to lower it properly could affect battery replacement operations and hinder the battery swap process. This is primarily due to the limited accuracy of the sensors used in traditional detection, making them difficult to adapt to the complex operating conditions of off-road environments. Furthermore, the sensor installation location is often inappropriate, and factors such as vehicle vibration during operation and dust in mining areas can easily interfere with the sensors. Previous attempts to improve sensor accuracy have failed to effectively address this issue due to the poor stability of high-precision sensors in harsh off-road environments, resulting in frequent misjudgments. Second, information exchange during the battery swap process is hindered. Signal delays and loss are common during information transmission between the vehicle and the battery swap station. Vehicles are unable to promptly and accurately transmit their status information, such as battery level, speed, and gear position, to battery swap stations. In turn, battery swap stations are unable to effectively and timely send commands to vehicles, such as lifting the cargo box or disengaging the vehicle. This disrupts the battery swap process, prolongs swap times, and reduces swap efficiency. This is due to the limitations of traditional communication technology. Signal transmission quality is difficult to guarantee in off-road environments, where signals are susceptible to obstruction and interference. Furthermore, inadequate communication protocols prevent accurate information transmission. Despite attempts to replace communication equipment and optimize protocols, signal issues persist due to the complexity of off-road environments. Thirdly, the battery swap process presents safety and efficiency risks. During the battery swap operation, imprecise connection and disconnection between the battery compartment and the vehicle results in a loose battery installation. Vibration and jolts during driving can cause the battery to loosen or even fall off, seriously threatening driving safety. Furthermore, low battery swap efficiency increases vehicle waiting time and reduces actual operating time. This is primarily due to the low precision and automation level of the battery swap equipment, as well as the lack of reliable positioning and securing devices. Improvements have been made to battery replacement equipment in the past, but due to the high cost of the equipment and the difficulty of technical implementation, it is difficult to promote and apply it on a large scale.

[0005] To sum up, the existing battery replacement methods for off-road pure electric wide-body vehicles have obvious shortcomings in cargo box position detection, information interaction, and battery replacement safety and stability. A new battery replacement method is urgently needed to solve these problems in order to promote the widespread application of off-road pure electric wide-body vehicles in fields such as mining transportation. Summary of the Invention

[0006] The present invention provides an off-road pure electric wide-body vehicle, which can realize fast, safe, reliable and efficient battery replacement, improve the working efficiency of the battery-swap off-road wide-body dump truck, and reduce operating costs.

[0007] The present invention also provides a battery replacement method for an off-road pure electric wide-body vehicle, which can accurately control the position of the cargo box, avoid the situation where the cargo box is lifted too high or not lowered into place, ensure the smooth progress of the battery replacement process, and improve the safety and efficiency of the battery replacement.

[0008] To achieve these objectives and other advantages of the present invention, an off-road pure electric wide-body vehicle is provided, comprising: a vehicle frame, a power system, a suspension system, a travel system, a cargo box, a cab assembly, a battery assembly, and further comprising:

[0009] A top dead center sensor plate and a top dead center proximity switch, wherein the top dead center sensor plate is mounted on the threaded plate at the rear of the cargo box, and the top dead center proximity switch is mounted on the rear plate of the vehicle frame. The top dead center proximity switch outputs a low level when the cargo box is lifted and separated from the top dead center sensor plate;

[0010] The bottom dead center sensor plate and bottom dead center proximity switch are installed on the threaded plates of the main crossbeam on both sides of the middle part of the cargo box, and the bottom dead center proximity switch is installed on the threaded plate in the middle part of the frame. The bottom dead center proximity switch outputs a high level when the cargo box drops and contacts the bottom dead center sensor plate;

[0011] The battery swap rocker switch is located on the vehicle dashboard in the cab and is used to respond to the user's battery swap command;

[0012] The vehicle controller sends wireless connection instructions by collecting signals from the battery swap rocker switch;

[0013] The on-board battery swap controller is connected to the vehicle controller via a CAN line, and is used to receive wireless connection instructions and activate the wireless communication module to establish a connection with the battery swap station;

[0014] Among them, the vehicle controller determines whether the cargo box is lifted or lowered into place through the low level and high level output by the top dead center proximity switch and the bottom dead center proximity switch, and sends the judgment signal to the battery swap station.

[0015] Preferably, the vehicle-mounted battery replacement controller performs the following operations:

[0016] a) After receiving the signal from the battery swap rocker switch, the vehicle controller verifies the signal stability and generates an encrypted connection request, which is sent to the on-board battery swap controller via the CAN bus;

[0017] b) The onboard battery swap controller selects a multi-band redundant connection strategy based on signal strength and interference level, prioritizing connection to the dedicated high-frequency band and switching to the cellular network when the signal degrades;

[0018] c) Establish time-sharing duplex communication with the battery swap station, transmit control instructions and status data in time-sharing mode, and attach checksums and serial numbers to instructions to filter out duplicate instructions;

[0019] d) When wireless communication is interrupted, the relative position is calculated based on the on-board sensor data, and the battery swap mechanism is controlled to perform offline battery swap operations at a conservative speed.

[0020] A battery replacement method for an off-road pure electric wide-body vehicle, using the off-road pure electric wide-body vehicle, includes:

[0021] The vehicle controller detects the vehicle status and sends a battery swap ready signal to the battery swap station when the vehicle speed is 0 km / h, the gear is in neutral, and the parking brake is in parking state;

[0022] The vehicle controller detects the status of the cargo box through the top dead center proximity switch. When the top dead center proximity switch outputs a low level due to the cargo box being lifted and separated from the top dead center sensor plate, it determines that the cargo box has been lifted to the designated position, stops lifting, and sends a lifting completion signal to the battery swap station.

[0023] After the vehicle controller detects that the vehicle is powered off, it sends a power-off confirmation signal to the battery swap station;

[0024] Replacement battery;

[0025] After the vehicle controller detects that the vehicle is powered on, it sends a power-on confirmation signal to the battery swap station;

[0026] The vehicle controller detects the status of the cargo box through the bottom dead center proximity switch. When the bottom dead center proximity switch outputs a high level due to the cargo box touching the bottom dead center sensor plate, it determines that the cargo box has landed in place and sends a landing completion signal to the battery swap station;

[0027] Battery replacement completed.

[0028] Preferably, the timing is started during the cargo box lifting process. If the top dead center proximity switch output is not detected to be low level within the preset time, the vehicle controller is forced to stop the lifting and send a fault signal to the battery swap station.

[0029] Preferably, the wireless network connection is also included before the cargo box is lifted:

[0030] When the vehicle controller detects that the vehicle battery power is lower than the set threshold, it triggers an alarm signal to remind the user to replace the battery;

[0031] After receiving the user's battery replacement instruction, the vehicle controller sends a wireless connection instruction to the on-board battery replacement controller;

[0032] The on-board battery swap controller starts the wireless communication module based on the wireless connection instruction and establishes a wireless connection with the battery swap station.

[0033] Preferably, after the vehicle controller sends a battery swap ready signal to the battery swap station, the battery swap station confirms the vehicle position and the battery swap ready signal through a sensor, and then issues a cargo box lifting instruction to remind the user to lift the cargo box;

[0034] After the vehicle controller sends a lifting completion signal to the battery swap station, the battery swap station issues a vehicle power-off command. After the vehicle controller detects the vehicle power-off status, it sends a power-off confirmation signal to the battery swap station to replace the battery.

[0035] After the battery replacement is completed, the battery swap station issues a vehicle power-on command. After the vehicle controller detects the vehicle power-on status, it sends a power-on confirmation signal to the battery swap station. After the battery swap station verifies that the battery status is normal, it issues a cargo box lowering command to remind the user to lower the cargo box.

[0036] After the vehicle controller sends a landing completion signal to the battery swap station, the battery swap station lifts the vehicle driving restrictions.

[0037] Preferably, the vehicle controller integrates a signal redundancy module for connecting the detection signals of the top dead center proximity switch and the bottom dead center proximity switch to two independent ADC channels respectively;

[0038] The two signals are cross-checked in real time. When the difference in the level status of the two signals lasts for more than 200 ms, the sensor is judged to be faulty and the system switches to manual operation mode.

[0039] Preferably, the battery replacement is achieved through a battery replacement actuator at a battery swap station, including:

[0040] The battery compartment position data is collected by a 3D vision camera and sent to the vehicle controller. The vehicle controller unlocks the locking device of the battery compartment base. The locking device includes a primary positioning device and a secondary positioning device. The primary positioning device is a conical structure formed by a square tube, and the secondary positioning device is a circular hole structure. The battery compartment and the battery compartment base are no longer hard-connected.

[0041] The telescopic fork mechanism moves to the bottom of the battery compartment according to the position data. After adjusting the fork level through the leveling mechanism, the battery compartment is lifted to a safe height away from the positioning device. The depleted battery compartment is removed and replaced with a fully charged battery compartment.

[0042] The vehicle controller locks the locking device, and the battery compartment and the battery compartment base are hard-connected.

[0043] The present invention has at least the following beneficial effects:

[0044] First, the present invention uses upper and lower dead center sensors in conjunction with proximity switches to accurately detect the lifting and lowering of the cargo box. This prevents damage to the vehicle structure caused by over-lifting the cargo box, and prevents battery replacement operations from being affected by improper lowering. This ensures a smooth battery replacement process and improves safety and efficiency.

[0045] Second, the present invention allows the user to operate the battery-swapping rocker switch, and the vehicle controller collects signals and controls the on-board battery-swapping controller to establish a wireless connection, which not only ensures the automated interaction of the battery-swapping process, but also fundamentally avoids the problem of functional limitation caused by incorrect connection of wireless signals, making the battery-swapping process more efficient.

[0046] Third, the present invention ensures the safety and stability of the battery replacement process by clarifying the steps and conditions for powering off and on the vehicle, lowering the cargo box, and lifting driving restrictions. It avoids the dangers of the vehicle accidentally starting or driving before the cargo box is lowered into place during the battery replacement process, and ensures the safety of the vehicle and personnel.

[0047] Fourth, the present invention ensures that the battery replacement instructions are not interfered with by accidental touches through a signal verification mechanism, thereby reducing the error operation rate. The multi-band redundant connection strategy adapts to complex terrain and improves communication stability. Time-sharing duplex communication and instruction deduplication reduce instruction conflicts and ensure the real-time performance of key actions. Offline battery replacement operation control maintains basic functions when communication is interrupted, thereby improving the system's fault tolerance.

[0048] Fifth, this invention upgrades the signal redundancy mechanism from simple level comparison to dynamic evaluation. Through the algorithm layer (difference calculation), hardware layer (ADC isolation), and control layer (graded response), it achieves the coordinated design of mechanical limit protection and hydraulic power cutoff, breaking through the traditional single power-off protection mode and ensuring equipment safety under extreme working conditions.

[0049] Sixth, the off-road pure electric wide-body vehicle of the present invention collects various sensor signals through the vehicle controller to accurately judge the vehicle status and exchange information with the battery swap station. The on-board battery swap controller is responsible for establishing a wireless connection with the battery swap station. The coordinated work of various systems realizes the automated control of the battery swap process, improves the efficiency and safety of battery swap, reduces manual intervention, and reduces operational errors.

[0050] Other advantages, objectives and features of the present invention will be reflected in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 A schematic structural diagram of an off-road pure electric wide-body vehicle according to a technical solution of the present invention;

[0052] Figure 2 This is a schematic diagram of the distribution of the top dead center proximity switch and the bottom dead center proximity switch according to a technical solution of the present invention;

[0053] Figure 3 A schematic diagram of the distribution of the top dead center induction plate of a technical solution of the present invention;

[0054] Figure 4This is a schematic diagram of the distribution of the bottom dead center induction plate of a technical solution of the present invention;

[0055] Figure 5 This is a detailed control process diagram of a battery swap method according to a technical solution of the present invention. DETAILED DESCRIPTION

[0056] The present invention will be described in further detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0057] It should be understood that terms such as “having”, “including” and “comprising” used herein do not preclude the existence or addition of one or more other elements or combinations thereof.

[0058] It should be noted that the experimental methods described in the following embodiments are conventional methods unless otherwise specified, and the reagents and materials are commercially available unless otherwise specified. In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected or set, or detachably connected or set, or integrally connected or set. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances. The orientations or positional relationships indicated by the terms "transverse", "longitudinal", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc. are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0059] Existing off-road pure electric wide-body vehicles have inaccurate detection of the cargo box's lifting and lowering positions during battery swapping, which can easily lead to over-lifting or under-lowering, affecting the smooth battery swap and vehicle safety. The present invention provides an off-road pure electric wide-body vehicle.

[0060] like Figure 1As shown, the off-road pure electric wide-body vehicle used to implement the battery swap method includes: a frame 5, a power system 6, a suspension system 7, a running system 8, a cargo box 9, a cab assembly 10, and a battery assembly 11. The frame 5 is connected to the power system 6, the suspension system 7, and the running system 8 to form the vehicle chassis. The cargo box 9, the battery assembly 11, and the cab assembly 10 are all mounted on the frame 5. The battery assembly 11 is mounted between the cab and the cargo box 9. The battery assembly 11 includes: a battery, a battery compartment, and a battery compartment base. The battery compartment is used to accommodate the battery, and the battery compartment base is fixedly connected to the frame 5; a locking device is fixedly provided on the battery compartment base, and the battery compartment is detachably mounted on the battery compartment base via the locking device; a lifting hole is provided on the top of the battery compartment for connection to the telescopic arm in the battery swap station, so that the battery swap station can grab the battery during battery swap. The battery compartment is made of rectangular tube materials overlapped to form a frame structure, and the battery compartment is covered with a skin to prevent foreign matter and water from entering the battery compartment. Among them, the locking device includes a primary positioning device, a secondary positioning device, and a locking device. The primary positioning device is a primary positioning device, and the secondary positioning device is a secondary positioning device. The primary positioning device is a cone device formed of a square tube, which has high strength and large bearing capacity; the secondary positioning device is in a round hole state. During hoisting, the secondary positioning is intervened only after the primary positioning is completed. Since the battery assembly 11 is installed behind the cab, the brim of the cargo box 9 will block the battery exchange. One end of the brim of the cargo box 9 needs to be lifted to take the battery out or put in. When the cargo box 9 is lifted too high, it is easy to collide with the top of the battery exchange station. In order to ensure the accuracy of the timing and angle of lifting and falling of the cargo box 9, the contact between the bottom stop point sensor plate 4 and the bottom stop point proximity switch 2 and the top stop point sensor plate 3 and the top stop point proximity switch 1 is used to know the status of the cargo box 9, such as Figure 2-4 As shown, it also includes:

[0061] The top dead center sensor plate 3 and the top dead center proximity switch 1, the top dead center sensor plate 3 is installed on the threaded plate at the rear of the cargo box 9 through two M10 bolts, and the top dead center proximity switch 1 is installed on the tail plate of the frame 5 through the switch fixing plate; the purpose of setting the top dead center switch is to detect whether the cargo box 9 is lifted into place, and the top dead center proximity switch 1 outputs a low level because the cargo box 9 is lifted and separated from the top dead center sensor plate 3, that is, when the top dead center proximity switch 1 can no longer detect the cargo box 9, it outputs a low level.

[0062] The bottom dead center sensor plate 4 and the bottom dead center proximity switch 2, the bottom dead center sensor plate 4 is installed on the threaded plate of the main crossbeam on both sides of the middle of the cargo box 9 through two M10 bolts, and the bottom dead center proximity switch 2 is installed on the threaded plate in the middle of the frame 5 through the switch fixing plate; the purpose of setting the bottom dead center proximity switch 2 is to detect whether the cargo box 9 has fallen into place, the bottom dead center proximity switch 2 outputs a high level because the cargo box 9 falls and contacts the bottom dead center sensor plate 4, that is, when the bottom dead center proximity switch 2 senses the cargo box 9, it outputs a high level.

[0063] The battery swap rocker switch is a device used by users to input battery swap commands to the vehicle controller. It is installed on the vehicle dashboard in the cab and is used to respond to the user's battery swap commands.

[0064] The vehicle controller sends wireless connection instructions by collecting signals from the battery swap rocker switch on the vehicle dashboard, and controls the on-board battery swap controller and the wireless network between the battery swap station through the rocker switch.

[0065] The on-board battery swap controller is connected to the battery swap station through a wireless network and communicates with the vehicle controller through a CAN line. It is used to receive wireless connection instructions, start the wireless communication module to establish a connection with the battery swap station, thereby realizing information interaction between the battery swap station and the vehicle controller. The on-board battery swap controller is responsible for monitoring and feedback of the battery swap status.

[0066] The vehicle controller collects various sensor signals to detect the vehicle status in real time, performs lifting and position detection of the cargo box 9, and meets the battery replacement conditions to ensure the safety of the vehicle's battery replacement. The vehicle controller controls the on-board battery replacement controller to turn on the wireless connection function by collecting signals from the rocker switch on the vehicle dashboard. The vehicle controller determines whether the cargo box 9 is lifted or lowered into place through the low and high levels output by the top dead center proximity switch 1 and the bottom dead center proximity switch 2, and sends the judgment signal to the battery replacement station.

[0067] In the above technical solution, when the vehicle needs to perform a battery swap and the cargo box 9 begins to lift, the top dead center sensor plate 3 at the rear of the cargo box 9 rises with it. The top dead center proximity switch 1 monitors the distance to the sensor plate in real time. When the cargo box 9 reaches a certain height, the top dead center proximity switch 1 disengages from the top dead center sensor plate 3, at which point the proximity switch outputs a low-level signal. Upon receiving this low-level signal, the vehicle controller determines that the cargo box 9 has reached its full height, immediately halts the lift, and transmits a lift completion signal to the battery swap station. Similarly, when the cargo box 9 needs to be lowered, the bottom dead center sensor plates 4 on either side of the center of the cargo box 9 move downward. Upon detecting contact with the bottom dead center proximity switches 2, the vehicle controller outputs a high-level signal. Upon receiving this high-level signal, the vehicle controller determines that the cargo box 9 has landed and transmits a landing completion signal to the battery swap station. The coordination of the top dead center sensor plates 3, 4, and the top dead center proximity switches 1 and 2 allows for precise detection of the lifting and lowering status of the cargo box 9. This avoids the problem of the cargo box 9 being lifted too high and causing damage to the vehicle structure, and the problem of the battery replacement operation being affected by not lowering it properly. It ensures the smooth progress of the battery replacement process and improves the safety and efficiency of battery replacement.

[0068] The vehicle communicates with the battery swap station wirelessly, and its signal coverage is uncontrollable (similar to the characteristics of Wi-Fi signals), and accidental connections may occur in areas outside the battery swap station (such as a nearby repair shop). Once the vehicle establishes a connection with the battery swap station, the battery swap station will automatically send a "battery swap standby status" signal. After this signal is transmitted to the vehicle controller via the CAN line, the vehicle controller will assume that the vehicle is in the battery swap area, and then impose restrictions on the lifting function of the cargo box 9 (only allowing the cargo box 9 to be lifted to a small angle of more than ten degrees to prevent collision with the top of the battery swap station). An on-board battery swap controller is set up to communicate with the vehicle controller via the CAN line and connect to the battery swap station via a wireless network, thereby realizing information exchange between the battery swap station and the vehicle controller.

[0069] In a maintenance scenario, if the vehicle has not entered the formal battery swap process but is accidentally connected to a battery swap station due to wireless signal coverage issues, the lifting limit of the cargo box 9 of the vehicle controller will cause the maintenance personnel to be unable to lift the cargo box 9 normally for maintenance work, seriously affecting the vehicle maintenance efficiency. When the driver needs to perform a battery swap operation, he manually presses the battery swap rocker switch, and the metal contacts of the switch close or disconnect, generating a corresponding electrical signal. The vehicle controller is connected to the instrument panel circuit and monitors the circuit signal changes in real time. When the signal change corresponding to the battery swap rocker switch is detected, it is identified as a battery swap instruction issued by the user and performs subsequent battery swap process control operations, such as sending a wireless connection instruction to the on-board battery swap controller. If the rocker switch is not turned on, even if the vehicle enters the wireless signal coverage area (such as a scenario where the repair shop and the battery swap station are adjacent), the on-board battery swap controller is always in a wireless connection disabled state to prevent the battery swap station from mistakenly sending a "battery swap standby state" signal. If the vehicle controller does not receive an activation signal from the rocker switch, it will not assume the vehicle is in the battery swapping area, thereby removing the lift angle restriction for cargo box 9 (cargo box 9 can be lifted to its full angle normally in non-battery swapping scenarios). This ensures that maintenance personnel can freely operate cargo box 9 during inspections and avoids functional limitations caused by incorrect connections. As a key node in human-computer interaction, the battery swap rocker switch ensures the real-time and accuracy of information exchange during battery swapping, while also preventing the vehicle controller from misjudging operating conditions due to interference from environmental signals. This fundamentally eliminates the abnormal limitation of the lift function of cargo box 9 in scenarios such as maintenance.

[0070] The battery swap rocker switch is susceptible to mechanical vibration or accidental touch during maintenance, which may generate erroneous instructions and may cause unexpected actions such as lifting the cargo box 9 or replacing the battery. In another technical solution, the on-board battery swap controller performs the following operations:

[0071] (a) After receiving the battery swap rocker switch signal, the vehicle controller verifies the signal stability and generates an encrypted connection request, which is sent to the on-board battery swap controller via the CAN bus. After verifying the stability, it generates an encrypted request containing the vehicle VIN code and timestamp. The vehicle controller collects the voltage signal of the battery swap rocker switch in real time. When a high-level signal is detected to last for more than 200 ms and there is no jump within 50 ms, it is determined to be a valid operation. Subsequently, the controller reads the vehicle VIN code, combines the internal RTC module to generate a timestamp accurate to milliseconds, encrypts the generated connection request frame using the AES-128 algorithm, and transmits it to the on-board battery swap controller via the CAN bus.

[0072] (b) The on-board battery swap controller selects a multi-band redundant connection strategy based on signal strength and interference level, prioritizes connecting to the dedicated high-frequency band, and switches to the cellular network when the signal degrades. For example, the on-board battery swap controller prioritizes connecting to the 5G-U band. When the signal degrades, that is, if the strength is lower than -90 dBm or the channel occupancy rate is detected to be more than 60%, it automatically switches to the LTE network and establishes a connection through the TCP protocol. When GPS fails, the inertial navigation data, acceleration and angular velocity data are combined with the pre-stored battery swap station coordinates to calculate the relative position of the vehicle and correct the antenna beam direction.

[0073] (c) Establish time-sharing duplex communication with the battery swap station, transmitting control commands and status data in a time-sharing manner. A checksum and serial number are appended to the commands to filter out duplicate commands. The onboard battery swap controller divides the communication cycle into 20 ms time slots. The first 5 ms sends an encrypted data packet containing lift and lowering commands, appended with a CRC-32 checksum and a 16-bit incrementing serial number. Upon receiving the data, the battery swap station verifies the CRC and compares the serial number. If three consecutive commands with the same serial number are received, the redundant data is discarded. Status data, including information such as battery voltage and cargo box angle, is transmitted in the final 15 ms time slot. The battery swap station actively discards commands with duplicate serial numbers to ensure action uniqueness.

[0074] (d) When wireless communication is interrupted for more than 5 seconds, the vehicle's relative position is calculated based on the on-board sensor data, acceleration and angular velocity data, combined with the coordinates of the battery swap station from the last communication. The battery swap station is controlled at a conservative speed, the fork movement speed is limited to 0.15 m / s, and an offline battery swap operation is performed. After the timeout, the process is terminated and the limit protection is activated to detect in real time whether the fork travel exceeds the limit.

[0075] In the above technical solution, the signal stability verification and encryption mechanism effectively filters out false touch commands, reduces the risk of false operation of the cargo box 9, time-sharing duplex communication isolates commands and data streams, reduces channel congestion, and the response delay of key actions is controllable. The offline battery replacement mode maintains basic functions when communication is interrupted, and combines low-speed operation with limit protection to avoid damage to the mechanical structure.

[0076] The battery replacement method of the off-road pure electric wide-body vehicle is applied to the off-road pure electric wide-body vehicle, such as Figure 5 As shown, the battery replacement method includes:

[0077] The vehicle controller detects the vehicle status and sends a battery swap ready signal to the battery swap station when the vehicle speed is 0 km / h, the gear is in neutral, and the parking brake is in parking state;

[0078] The vehicle controller detects the status of the cargo box 9 through the top dead center proximity switch 1. When the top dead center proximity switch 1 outputs a low level due to the cargo box 9 being lifted and separated from the top dead center sensor plate 3, it determines that the cargo box 9 has been lifted to the designated position, stops lifting, and sends a lifting completion signal to the battery swap station;

[0079] After the vehicle controller detects that the vehicle is powered off, it sends a power-off confirmation signal to the battery swap station;

[0080] Replacement battery;

[0081] After the vehicle controller detects that the vehicle is powered on, it sends a power-on confirmation signal to the battery swap station;

[0082] The vehicle controller detects the status of the cargo box 9 through the bottom dead center proximity switch 2. When the bottom dead center proximity switch 2 outputs a high level due to the cargo box 9 touching the bottom dead center sensor plate 4, it determines that the cargo box 9 has landed in place and sends a landing completion signal to the battery swap station;

[0083] Battery replacement completed.

[0084] In the above technical solution, after the vehicle arrives at the battery swap station and comes to a complete stop, the vehicle controller detects that the vehicle speed is 0 km / h, the gear is in neutral, and the parking brake is in the parking state, and sends a battery swap ready signal to the battery swap station. The battery swap station notifies the vehicle to lift the cargo box 9, and the vehicle controller controls the lifting of the cargo box 9 and times it, and determines the lifting status of the cargo box 9 based on the signal from the top dead center proximity switch 1. After the cargo box 9 is lifted into place, the battery swap station notifies the vehicle to power off, and the vehicle controller controls the power off and sends a power off confirmation signal. After the battery swap is completed, the battery swap station notifies the vehicle to power on, and the vehicle controller controls the power on and sends a power on confirmation signal. Then, the vehicle controller determines the lowering status of the cargo box 9 based on the signal from the bottom dead center proximity switch 2, and sends a lowering completion signal after it has lowered into place.

[0085] Abnormalities may occur during the lifting process of the cargo box 9, such as a proximity switch failure causing the cargo box 9 to over-lift, posing a safety hazard. In another technical solution, the vehicle controller (VCU) starts a timer during the lifting process. If the preset lifting time limit (i.e., the time limit set for the lifting of the cargo box 9) is exceeded and the top dead center proximity switch 1 still does not output a low level, the lifting of the cargo box 9 is forcibly stopped and a fault signal is transmitted to the battery swap station. During the lifting process, the VCU continuously monitors the signal from the top dead center proximity switch 1. If the top dead center proximity switch 1 outputs a low level due to the lifting of the cargo box 9 disengaging the top dead center sensor plate 3 within the preset lifting time limit (e.g., 30 seconds), the VCU determines that the cargo box 9 has reached its designated position and stops the lifting operation. If, after 30 seconds, the VCU still does not detect a low level from the top dead center proximity switch 1, this indicates an abnormality in the lifting of the cargo box 9. The VCU then forcibly stops the lifting of the cargo box 9 and transmits a fault signal to the battery swap station via the CAN line, notifying the station for inspection and resolution.

[0086] In the above technical solution, the lifting time of the cargo box 9 is monitored by a timer, and the lifting is normal according to the signal of the top dead center proximity switch 1. If the lifting signal is not received after the preset time, it is determined to be abnormal and corresponding measures are taken. This can effectively prevent excessive lifting of the cargo box 9 due to failure of the top dead center proximity switch 1 or other reasons, protect the vehicle and the battery swap station equipment, and improve the safety and reliability of the battery swap process.

[0087] In another technical solution, a wireless network connection is also included before the cargo box 9 is lifted, that is, the vehicle establishes a communication connection with the battery swap station through the wireless communication module of the on-board battery swap controller:

[0088] When the vehicle controller detects that the vehicle battery power is lower than the set threshold (such as 20%), it triggers an alarm signal to remind the user to replace the battery. The alarm signal can be a low battery icon display on the vehicle dashboard and a voice prompt.

[0089] The battery-swap rocker switch installed in the cab is the device for users to input battery-swap commands. The vehicle controller receives the user's battery-swap commands by collecting signals from the battery-swap rocker switch on the vehicle's dashboard.

[0090] After receiving the user's battery replacement command, the vehicle controller sends a wireless connection command to the on-board battery replacement controller.

[0091] The on-board battery swap controller starts the wireless communication module, such as a Wi-Fi module or a 4G / 5G communication module, based on the wireless connection instruction to establish a wireless connection with the battery swap station.

[0092] In the above technical solution, the on-board battery swap controller communicates with the vehicle controller via a CAN line and connects to the battery swap station via a wireless network, thereby enabling information exchange between the battery swap station and the vehicle controller. The on-board battery swap controller is responsible for dedicated communication and logic processing for the entire battery swap process, decoupling battery swap communication from vehicle control, avoiding overload of the vehicle controller, and realizing functional specialization. Through a controllable wireless connection mechanism, the automated interaction of the battery swap process is guaranteed, and functional limitations caused by incorrect wireless signal connection are fundamentally avoided. While the vehicle is in operation, the vehicle controller monitors the vehicle status in real time through various sensors. When the battery charge is lower than a preset charge (for example, 20%), the user is reminded to swap the battery. The user operates the battery swap rocker switch, and the vehicle controller collects the signal and sends a wireless connection command to the on-board battery swap controller. The on-board battery swap controller activates the wireless communication module to establish a connection with the battery swap station. If the lifting of the cargo box 9 is abnormal, the vehicle controller forcibly stops the lifting and sends a fault signal. Ultimately, through the coordinated work of these devices and the vehicle controller, information exchange between the vehicle and the battery swap station and automatic control of the battery swap process are realized, which improves the efficiency and safety of the battery swap and ensures the smooth progress of the battery swap process.

[0093] In another technical solution, after the vehicle controller sends a battery swap ready signal to the battery swap station, the battery swap station confirms the vehicle position and the battery swap ready signal through sensors, and then issues a cargo box lifting instruction to remind the user to lift the cargo box 9.

[0094] Information exchange is achieved, namely the process of transmitting status information and commands between the vehicle and the battery swap station. The vehicle controller monitors the vehicle status in real time. The vehicle speed sensor, gear sensor, and parking brake sensor respectively detect the vehicle speed, gear position, and parking brake status. When the vehicle speed reaches 0 km / h, the gear is in neutral, and the parking brake is in park, a battery swap readiness signal is sent to the battery swap station. After the battery swap station confirms the vehicle's position and the battery swap readiness signal through sensors, it issues a cargo box lift command, reminding the user to lift the cargo box 9.

[0095] After the vehicle controller sends a lifting completion signal to the battery swap station, the battery swap station issues a vehicle power-off command, which cuts off the vehicle's high-voltage power supply and puts the vehicle in a non-operating state. The vehicle power-off is achieved by cutting off the vehicle's high-voltage power supply. A relay-type high-voltage disconnect switch can be used. After the vehicle controller detects the vehicle's power-off status, it sends a power-off confirmation signal to the battery swap station to replace the battery.

[0096] After the battery replacement is completed, the battery swap station issues a vehicle power-on command, that is, connects the high-voltage power supply to restore the vehicle's operating ability. The vehicle is powered on by connecting the high-voltage power supply, and a relay-type high-voltage on-switch is also used. After the vehicle controller detects the vehicle's power-on status, it sends a power-on confirmation signal to the battery swap station. After the battery swap station verifies that the battery status is normal, it issues a cargo box lowering command to remind the user to lower the cargo box 9.

[0097] After the vehicle controller sends a landing completion signal to the battery swap station, the battery swap station lifts the vehicle driving restrictions.

[0098] In the above technical solution, the vehicle controller continuously monitors the battery charge level while the vehicle is in operation, alerting the user when the charge level drops below a threshold. When the user operates the battery swap rocker switch, the vehicle controller collects the signal and controls the onboard battery swap controller to establish a wireless connection. Various sensors then detect the vehicle's status, and when conditions are met, information is exchanged with the battery swap station. This allows the vehicle to communicate with the station in an orderly manner when the battery level is low, preparing for the battery swap operation. Ultimately, this improves the timeliness and accuracy of battery swaps, reduces unnecessary waiting time, and makes the battery swap process more efficient.

[0099] The battery swap station issues a power-off command based on the lift status of the cargo box 9. The vehicle controller controls the vehicle's power-off and sends back a confirmation signal. After the battery swap is complete, the station issues a power-on command, which the vehicle controller controls and sends back a confirmation signal. After verifying the battery status is normal, the station instructs the cargo box 9 to lower. Once it is in place, the driving restrictions are lifted. By clearly defining the steps and conditions for powering off and on, lowering the cargo box 9, and lifting the driving restrictions, the safety and stability of the battery swap process are guaranteed, avoiding the dangers of accidentally starting the vehicle during the battery swap or driving before the cargo box 9 is fully lowered, and ensuring the safety of both vehicle and personnel.

[0100] Traditional single-channel detection solutions lack the ability to monitor sensor failures in real time, and are unable to promptly identify faults when they occur. This can lead to interruptions in the battery swap process or uncontrolled movement of the cargo box 9, posing a safety hazard. In another technical solution, the vehicle controller integrates a signal redundancy module to connect the detection signals of the top dead center proximity switch 1 and the bottom dead center proximity switch 2 to two independent ADC channels respectively;

[0101] The two signals are cross-checked in real time. When the difference in the level status of the two signals lasts for more than 200 ms, the sensor is judged to be faulty and the system switches to manual operation mode.

[0102] Specifically, the signal redundancy module performs the following operations:

[0103] (a) The detection signals from top dead center proximity switch 1 and bottom dead center proximity switch 2 are connected to two independent ADC channels. The sampling rate of these two ADC channels must be no less than 1 kHz, and the physical isolation must be greater than 60 dB. The high sampling rate (1 kHz) and physical isolation (60 dB) ensure signal acquisition accuracy and address noise interference issues in the complex electromagnetic environment of mining areas.

[0104] (b) Perform real-time cross-check on the two signals, including:

[0105] Calculate the level difference between the two signals in a 200 ms time window. The difference calculation formula is:

[0106]

[0107] in, S 1( t )and S 2( t ) are the quantized values of the two signals, T = 200ms;

[0108] when D If the error is ≥ 30% and lasts for more than 200 ms, it is considered a sensor failure.

[0109] Through the difference formula ( D ≥30%) quantifies signal anomalies to avoid misjudgments caused by a single time threshold (such as brief interference). The difference threshold (30%) can be dynamically adjusted based on historical fault data. For example, it can be automatically increased to 40% after three consecutive faults to reduce false alarm rates.

[0110] (c) Triggering the fault response mechanism:

[0111] Send fault codes and operation instructions to the vehicle's human-machine interface, including an operation button to switch to manual mode;

[0112] If the driver does not respond within 10 seconds, the vehicle controller automatically reduces the lifting / lowering speed of the cargo box 9 to 50% of the rated value and activates the mechanical limit protection. The manual operation guidance and the automatic speed reduction mechanism form a double protection to prevent the cargo box 9 from losing control due to sensor failure.

[0113] (d) In manual operation mode, the vehicle controller continuously monitors the lift / lowering commands input by the driver. If the logical conflict between the command and the sensor signal lasts for more than 5 seconds, the hydraulic power is forcibly cut off and an audible and visual alarm is triggered. The power is cut off after 5 seconds to prevent the driver from causing a mechanical collision due to incorrect operation.

[0114] In the above technical solution, the signal redundancy mechanism is upgraded from simple level comparison to dynamic evaluation. Through the algorithm layer (difference calculation), hardware layer (ADC isolation), and control layer (graded response), the coordinated design of mechanical limit protection and hydraulic power cut-off is realized, breaking through the traditional single power-off protection mode and ensuring equipment safety under extreme working conditions.

[0115] During the battery replacement process, the positioning of the battery compartment is inaccurate, the replacement efficiency is low, and the stability of the battery installation is insufficient. In another technical solution, the battery replacement is achieved by controlling the telescopic fork mechanism at the battery swap station, wherein the battery swap actuator at the battery swap station includes a 3D vision camera, a telescopic fork mechanism, a primary positioning device, and a secondary positioning device. The 3D vision camera is used to collect the position data of the battery compartment and is installed at the detection position at the entrance of the battery swap station; the telescopic fork mechanism is a device used to replace the battery; the primary positioning device and the secondary positioning device are structures used to fix the battery compartment. Replacing the battery includes:

[0116] When the vehicle enters the battery swap station and is accurately positioned, the battery compartment position data is collected through a 3D vision camera. That is, the 3D vision camera captures the spatial position of the battery cover panels on both sides of the battery compartment, calculates the spatial position between the two sides of the battery compartment and the battery swap compartment, and sends it to the vehicle controller.

[0117] After receiving the information, the vehicle controller sends a locking device unlocking command, and the vehicle controller unlocks the locking device of the battery compartment base. The locking device includes a primary positioning device and a secondary positioning device. The primary positioning device is a conical structure formed by a square tube, and the secondary positioning device is a circular hole structure. The battery compartment and the battery compartment base are out of the hard connection state.

[0118] The telescopic fork mechanism consists of a fixed arm, a drive motor, a telescopic arm, and a leveling mechanism. The fixed arm is located on the battery swap station's rotating axis, while the telescopic arm is located on the fixed arm. The drive rack is located on the telescopic arm, and the drive motor's drive shaft is connected to the drive gear. The drive rack is located on the telescopic arm. The drive motor drives the telescopic arm through the drive gear and drive rack. The leveling mechanism uses an electro-hydraulic leveling mechanism to adjust the vertical level of the forks. The telescopic fork mechanism moves to the bottom of the battery compartment based on the position data. The leveling mechanism adjusts the fork level and then lifts the battery compartment to a safe height to clear the positioning device. The depleted battery compartment is then removed and replaced with a fully charged one.

[0119] Afterwards, the drive motor is accurately aligned with the battery compartment base according to the position information again, and the vehicle controller sends a locking command to the locking device. The vehicle controller locks the locking device, and the battery compartment and the battery compartment base are hard-connected again.

[0120] In this technical solution, a 3D vision camera provides accurate battery compartment position data, which the vehicle controller uses to unlock and lock the locking device. The telescopic fork mechanism moves and operates based on this position data to facilitate battery replacement. Ultimately, this approach improves battery replacement accuracy and efficiency, ensures stable battery installation, reduces failures caused by improper battery installation, and enhances vehicle reliability.

[0121] In one example, Figure 5As shown, the detailed control process of the power station method is as follows:

[0122] When the vehicle controller detects that the battery power is lower than the set threshold, the instrument panel will display a low battery prompt and output a voice alarm;

[0123] The driver manually turns on the battery swap rocker switch in the cab, and the vehicle controller sends a wireless connection command to the onboard battery swap controller via the CAN bus;

[0124] The on-board battery swap controller activates the wireless communication module to establish a connection with the battery swap station. The driver drives the vehicle into the designated area of the battery swap station and stops the vehicle, shifts the vehicle into neutral, and applies the parking brake.

[0125] After the vehicle controller detects that the vehicle speed is 0 km / h, the gear is in neutral, and the parking brake is in parking state, it sends a battery swap ready signal to the battery swap station;

[0126] After the battery swap station confirms the vehicle's position and the battery swap readiness signal through sensors, it issues a cargo box lift command to the driver;

[0127] The driver manually lifts the cargo box 9, and the vehicle controller detects the status of the cargo box 9 through the top dead center proximity switch 1. When the top dead center proximity switch 1 outputs a low level, it determines that the lifting is in place, stops lifting, and sends a lifting completion signal to the battery swap station;

[0128] After the battery swap station receives the lifting completion signal, it broadcasts to the driver to turn off the vehicle key power. The vehicle controller detects the power-off state and sends a power-off confirmation signal.

[0129] The battery swap station controls the telescopic fork mechanism to perform the battery replacement, including: a 3D vision camera collects battery compartment position data and sends it to the vehicle controller, which unlocks the locking device of the battery compartment base; the telescopic fork mechanism moves to the bottom of the battery compartment based on the position data, adjusts the fork level using the leveling mechanism, and then lifts the battery compartment to a safe height to clear the positioning device, replaces the fully charged battery, and locks the locking device;

[0130] The battery swap station broadcasts the driver to power on the vehicle, and the vehicle controller detects the power-on status and sends a power-on confirmation signal;

[0131] After verifying that the battery status is normal, the battery swap station notifies the driver to land the cargo box 9. The vehicle controller detects the status of the cargo box 9 through the bottom dead center proximity switch 2. When the bottom dead center proximity switch 2 outputs a high level, it determines that the cargo box has landed and sends a landing completion signal to the battery swap station.

[0132] The battery swap station removes the driving restrictions and the vehicle controller allows the vehicle to drive.

[0133] In one example, the detailed battery swapping process at a battery swap station is as follows:

[0134] When a vehicle enters the battery swap station and accurately positions itself, a 3D vision camera captures the spatial position of the battery covers on either side of the battery compartment, calculates the spatial position between the battery compartment and the swap compartment (there will be errors on the left and right sides of the vehicle when it arrives at the swap station, so calibration is required before swapping at the station), and transmits this position information to the vehicle controller. After the position is calculated, the vehicle controller sends a command to unlock the locking device, disconnecting the battery compartment from the battery base. After the vehicle controller sends a signal to start swapping, the telescopic arm of the swap arm begins to remove the battery and install it on the vehicle.

[0135] Based on the calculated position information, the drive motor precisely aligns the battery compartment. The telescopic arm of the battery swap station's telescopic fork mechanism drives the fork to the bottom of the battery compartment. The two forks on one side are vertically leveled by a leveling mechanism to level the work surface. The forks are then raised until the bottom of the battery compartment is a safe distance above the primary positioning device. The forks then retract, depositing the batteries into the transfer battery warehouse.

[0136] The telescopic fork mechanism of the battery swap station picks up fully charged batteries from the transit battery warehouse, and places the fully charged batteries into the battery compartment through the telescopic fork mechanism. The battery compartment fork is moved above the bottom support of the battery compartment, and the 3D vision camera captures the spatial position of the battery cover plates on both sides of the battery compartment, calculates the spatial position of the batteries on both sides, and transmits the position information to the vehicle controller.

[0137] The driving motor accurately aligns the battery compartment bottom support based on the calculated position information, and the telescopic fork mechanism moves to the bottom of the battery compartment. The two forks on one side make the working surface level in the vertical direction through the leveling mechanism. At this time, the fork is raised until the bottom height is higher than a certain safety distance from the first-level positioning device. The vehicle controller sends an unlocking command to lock the locking device. The positioning is determined by the first-level positioning device and the second-level positioning device, and the vehicle controller sends a locking command to the locking device.

[0138] The number of devices and processing scales described herein are intended to simplify the description of the present invention. Applications, modifications, and variations of the present invention will be readily apparent to those skilled in the art.

[0139] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the description and implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. Off-road pure electric wide-body vehicles, including: The vehicle frame, power system, suspension system, travel system, cargo box, cab assembly, and battery assembly are characterized in that they also include: A top dead center sensor plate and a top dead center proximity switch, wherein the top dead center sensor plate is mounted on the threaded plate at the rear of the cargo box, and the top dead center proximity switch is mounted on the rear plate of the vehicle frame. The top dead center proximity switch outputs a low level when the cargo box is lifted and separated from the top dead center sensor plate; The bottom dead center sensor plate and bottom dead center proximity switch are installed on the threaded plates of the main crossbeam on both sides of the middle part of the cargo box, and the bottom dead center proximity switch is installed on the threaded plate in the middle part of the frame. The bottom dead center proximity switch outputs a high level when the cargo box drops and contacts the bottom dead center sensor plate; The battery swap rocker switch is located on the vehicle dashboard in the cab and is used to respond to the user's battery swap command; The vehicle controller sends wireless connection instructions by collecting signals from the battery swap rocker switch; The on-board battery swap controller is connected to the vehicle controller via a CAN line, and is used to receive wireless connection instructions and activate the wireless communication module to establish a connection with the battery swap station; The vehicle controller determines whether the cargo box is lifted or lowered into place through the low level and high level output by the top dead center proximity switch and the bottom dead center proximity switch, and sends the judgment signal to the battery swap station; The vehicle-mounted battery replacement controller performs the following operations: a) After receiving the signal from the battery swap rocker switch, the vehicle controller verifies the signal stability and generates an encrypted connection request, which is sent to the on-board battery swap controller via the CAN bus; b) The onboard battery swap controller selects a multi-band redundant connection strategy based on signal strength and interference level, prioritizing connection to the dedicated high-frequency band and switching to the cellular network when the signal degrades; c) Establish time-sharing duplex communication with the battery swap station, transmit control instructions and status data in time-sharing mode, and attach checksums and serial numbers to instructions to filter out duplicate instructions; d) When wireless communication is interrupted, the relative position is calculated based on the on-board sensor data, and the battery swap mechanism is controlled to perform offline battery swap operations at a conservative speed.

2. A battery replacement method for an off-road pure electric wide-body vehicle, characterized in that: Applying the off-road pure electric wide-body vehicle according to claim 1, the battery replacement method includes: The vehicle controller detects the vehicle status and sends a battery swap ready signal to the battery swap station when the vehicle speed is 0 km / h, the gear is in neutral, and the parking brake is in parking state; The vehicle controller detects the status of the cargo box through the top dead center proximity switch. When the top dead center proximity switch outputs a low level due to the cargo box being lifted and separated from the top dead center sensor plate, it determines that the cargo box has been lifted to the designated position, stops lifting, and sends a lifting completion signal to the battery swap station. After the vehicle controller detects that the vehicle is powered off, it sends a power-off confirmation signal to the battery swap station; Replacement battery; After the vehicle controller detects that the vehicle is powered on, it sends a power-on confirmation signal to the battery swap station; The vehicle controller detects the status of the cargo box through the bottom dead center proximity switch. When the bottom dead center proximity switch outputs a high level due to the cargo box touching the bottom dead center sensor plate, it determines that the cargo box has landed in place and sends a landing completion signal to the battery swap station; Battery replacement completed.

3. The battery replacement method for an off-road pure electric wide-body vehicle according to claim 2, characterized in that: The timing is started during the cargo box lifting process. If the top dead center proximity switch output is not detected to be low level within the preset time, the vehicle controller will force the lifting to stop and send a fault signal to the battery swap station.

4. The battery replacement method for an off-road pure electric wide-body vehicle according to claim 2, characterized in that: Also includes wireless connectivity before the cargo box is raised: When the vehicle controller detects that the vehicle battery power is lower than the set threshold, it triggers an alarm signal to remind the user to replace the battery; After receiving the user's battery replacement instruction, the vehicle controller sends a wireless connection instruction to the on-board battery replacement controller; The on-board battery swap controller starts the wireless communication module based on the wireless connection instruction and establishes a wireless connection with the battery swap station.

5. The battery replacement method for an off-road pure electric wide-body vehicle according to claim 2, characterized in that: After the vehicle controller sends a battery swap ready signal to the battery swap station, the station confirms the vehicle's position and the battery swap ready signal through sensors, and then issues a cargo box lift command to remind the user to lift the cargo box; After the vehicle controller sends a lifting completion signal to the battery swap station, the battery swap station issues a vehicle power-off command. After the vehicle controller detects the vehicle power-off status, it sends a power-off confirmation signal to the battery swap station to replace the battery. After the battery replacement is completed, the battery swap station issues a vehicle power-on command. After the vehicle controller detects the vehicle power-on status, it sends a power-on confirmation signal to the battery swap station. After the battery swap station verifies that the battery status is normal, it issues a cargo box lowering command to remind the user to lower the cargo box. After the vehicle controller sends a landing completion signal to the battery swap station, the battery swap station lifts the vehicle driving restrictions.

6. The battery replacement method for an off-road pure electric wide-body vehicle according to claim 2, characterized in that: The vehicle controller integrates a signal redundancy module for connecting the detection signals of the top dead center proximity switch and the bottom dead center proximity switch to two independent ADC channels respectively; The two signals are cross-checked in real time. When the difference in the level status of the two signals lasts for more than 200ms, the sensor is judged to be faulty and the system switches to manual operation mode.

7. The battery replacement method for an off-road pure electric wide-body vehicle according to claim 2, characterized in that: Battery replacement is achieved through the battery replacement actuator of the battery swap station, including: The battery compartment position data is collected by a 3D vision camera and sent to the vehicle controller. The vehicle controller unlocks the locking device of the battery compartment base. The locking device includes a primary positioning device and a secondary positioning device. The primary positioning device is a conical structure formed by a square tube, and the secondary positioning device is a circular hole structure. The battery compartment and the battery compartment base are no longer hard-connected. The telescopic fork mechanism moves to the bottom of the battery compartment according to the position data. After adjusting the fork level through the leveling mechanism, the battery compartment is lifted to a safe height away from the positioning device. The depleted battery compartment is removed and replaced with a fully charged battery compartment. The vehicle controller locks the locking device, and the battery compartment and the battery compartment base are hard-connected.

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