An electric change system and method for an underground trackless mine car

Abstract

The application discloses a battery replacement system and method for a trackless mine car underground, and the battery replacement system comprises a front vehicle frame, a battery replacement module assembly arranged on a mounting area of the front vehicle frame, a guiding mechanism for guiding dismounting and mounting of the battery replacement module assembly, and a locking mechanism for locking the battery replacement module assembly; the battery replacement module assembly is connected with the vehicle through a self-positioning battery replacement connector to realize high-voltage electrical connection and low-voltage communication connection; the self-positioning battery replacement connector comprises a vehicle end connector arranged on the front vehicle frame and a battery end connector arranged on the battery replacement module assembly; the guiding mechanism comprises guiding columns and positioning pins arranged on the bottom of the battery replacement module assembly and guiding and positioning structures arranged on the rear side, the front side and the left side of the vehicle frame; and the locking mechanism comprises a locking pin and an operating rod assembly for driving the locking pin to stretch and retract. The application has the advantages of compact structure, high space utilization, simple operation, safety and reliability, and locking and unlocking through an independent mechanical locking mechanism.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mine cars, in particular to a battery replacement system and method for underground trackless mine cars. BACKGROUND

[0002] Compared with traditional fuel vehicles, pure electric driving underground trackless mine cars eliminate exhaust gas and engine noise generated during diesel combustion, have the advantages of zero emission and low noise, improve the underground roadway operation environment, and also reduce the risk of damage to the operator's hearing. In addition, pure electric driving underground trackless mine cars are more energy-saving, efficient and low-maintenance during operation, so pure electric driving underground trackless mine cars are the choice for the development of underground mine transportation in the direction of green and low carbon.

[0003] With the rapid development of mine construction, the work efficiency requirements of pure electric driving vehicles by the mine side are also increasing. Not only do pure electric driving vehicles require longer endurance time, but the energy replenishment efficiency has also become the focus of more people. The unique "vehicle and battery separation" mode of the battery replacement mode saves the charging time and has the advantage of high energy replenishment efficiency, providing a quick energy replenishment way for pure electric products. The quick energy replenishment of the battery replacement mode requires that the battery replacement vehicle must have a matching battery replacement method, that is, when the battery needs to be replaced, the battery replacement module assembly integrating the power battery system and the thermal management system inside is quickly unlocked through the provided battery replacement structure, and then the entire battery replacement module assembly is separated from the vehicle frame. Then, the full-battery battery replacement module assembly is installed on the vehicle frame and is quickly locked.

[0004] At present, the battery replacement method of mine-used battery replacement vehicles can be divided into self-replacement and non-self-replacement according to whether additional equipment is needed. The self-replacement type does not need a high-altitude crane or external infrastructure assistance during battery replacement, and can complete the battery replacement operation through the self-replacement system provided by itself. The non-self-replacement type needs to use a crane or a mechanical arm as an "vehicle and battery separation" execution mechanism, and realizes the limit locking through the battery replacement structure provided by the vehicle itself.

[0005] The self-replacement type does not need auxiliary equipment, and the battery replacement is flexible and not limited by auxiliary equipment, but the self-replacement system structure is complex, and an additional battery is needed as a power source during the battery replacement process of the self-replacement system, which is high in cost. In addition, the battery replacement module assembly of the self-replacement type is generally arranged at the end (tail) of the vehicle, which occupies a large space and is not friendly to the overall vehicle layout.

[0006] Non-self-exchange type battery replacement, whether it is top lifting type battery replacement or side type battery replacement, most of them are through the battery replacement bottom support installed on the vehicle frame or other support structure to cooperate with the battery replacement module assembly to achieve the purpose of successful battery replacement module assembly on the vehicle limiting and locking. Among them, due to the cooperation structure required for guiding, positioning and locking in the battery replacement process is provided on the bottom support or other support structure, which occupies a certain installation space, increases the difficulty of vehicle layout, and the same is true on the battery replacement module assembly. SUMMARY

[0007] The technical problem to be solved by the present application is to provide an underground trackless mine car battery replacement system and method, and the battery replacement structure is directly arranged on the corresponding position of the battery replacement module assembly and the front frame, which is compact in structure and high in space utilization. The independent mechanical locking mechanism is used for locking and unlocking, which is simple to operate, safe and reliable.

[0008] To solve the above technical problems, the technical scheme of the present application is: an underground trackless mine car battery replacement system, comprising a front frame, a battery replacement module assembly arranged in the installation area of the front frame, a guide mechanism for guiding the disassembly and assembly of the battery replacement module assembly, and a locking mechanism for locking the battery replacement module assembly.

[0009] The installation area is surrounded by a cover arranged in front of the front frame, a cab arranged on the left side of the front frame and a front wheel mudguard, and the front frame comprises a bottom plate, an installation plate arranged above the bottom plate and arranged horizontally, and a support plate arranged between the bottom plate and the installation plate.

[0010] The battery replacement module assembly comprises a power battery box, a power battery pack, a control box, a high-voltage box, a power supply control box, a thermal management unit and a thermal management expansion tank, the power battery pack is arranged in the power battery box, the high-voltage box, the power supply control box, the thermal management unit and the thermal management expansion tank are arranged in the control box, the control box is arranged on one side of the power battery box, and the top of the power battery box is provided with an lifting lug.

[0011] The battery replacement module assembly realizes high-voltage electrical connection and low-voltage communication connection with the vehicle through a self-positioning battery replacement connector, and the self-positioning battery replacement connector comprises a vehicle end connector arranged on the front frame and a battery end connector arranged on the battery replacement module assembly.

[0012] The guiding mechanism comprises a lateral guiding column, a longitudinal guiding column, a positioning pin, a left guiding alignment structure, a rear guiding alignment structure and a front guiding alignment structure, the lateral guiding column, the longitudinal guiding column and the positioning pin are arranged on the bottom of the battery replacement module assembly, the bottom surface of the battery replacement module assembly is matched with a mounting plate, the mounting plate is provided with a positioning pin hole matched with the positioning pin, the front frame is provided with guiding grooves matched with the lateral guiding column and the longitudinal guiding column, the left guiding alignment structure is arranged on the cab, the front guiding alignment structure is arranged on the front frame and located in front of the mounting area, and the rear guiding alignment structure is arranged on the front frame and located behind the mounting area.

[0013] The locking mechanism comprises a locking pin working hole arranged on the support plate, a locking pin seat arranged on the bottom of the battery replacement module assembly, a locking pin matched with the locking pin working hole and the locking pin seat, a travel switch for detecting the position of the locking pin, an operating rod connected with the locking pin, a hand wheel for rotating the operating rod and an operating rod seat, the operating rod seat is fixed on the right side surface of the front frame, the operating rod is threadedly matched with the operating rod seat, and the front end of the operating rod is rotationally matched with the locking pin.

[0014] As an improvement, the top of the power battery box body is provided with four rectangularly distributed lifting lugs, the lifting lugs are matched with lifting devices, the lifting devices are H-shaped and comprise a cross beam and lifting arms arranged at both ends of the cross beam, and both ends of the lifting arms are provided with convex columns matched with the lifting lugs.

[0015] As an improvement, the battery end connector is arranged on the bottom of the control box body, the vehicle end connector is arranged on a mounting bracket, the mounting bracket is arranged on the front frame, an avoiding space is formed between the bottom surface of the control box body and the side surface of the power battery box body, the mounting bracket is arranged in the avoiding space, and the side surface of the battery replacement module assembly is provided with a movable cover plate corresponding to the position of the avoiding space.

[0016] As an improvement, the side surface of the control box body is provided with a charging socket, a high-voltage electricity state indicating lamp and a locking pin state indicating lamp.

[0017] As an improvement, one lateral guiding column and one longitudinal guiding column form a guiding assembly, and the bottom of the power battery box body is provided with four rectangularly distributed guiding assemblies.

[0018] As an improvement, the bottom of the battery replacement module assembly is provided with a damping cushion, and the side surface of the battery replacement module assembly is provided with a buffer wear-resistant plate.

[0019] As improvement, the left guiding alignment structure, the rear guiding alignment structure and the front guiding alignment structure all include a vertical column and an inclined block arranged at the upper end of the vertical column, the left guiding alignment structure and the front guiding alignment structure are flush with each other and higher than the rear guiding alignment structure; the transverse guide column and the longitudinal guide column all include a vertical plate and a 45-degree inclined plate connected with the vertical plate, and a wear-resistant limiting plate is arranged in the guide groove and attached to the vertical plate.

[0020] As improvement, the side surface of the front frame is provided with an operation cabin, the operation lever seat is arranged in the operation cabin, the operation lever includes a lever rod and a lever sleeve sleeved on the lever rod, and the operation lever seat includes a fixed plate and a cylindrical nut arranged in the middle of the fixed plate, the lever sleeve is inserted into the cylindrical nut and threadedly matched with the cylindrical nut.

[0021] As improvement, the front frame is provided with a pin shaft cylinder, the pin shaft cylinder is U-shaped, and the locking pin passes through the pin shaft cylinder.

[0022] The battery replacement method comprises the following steps:

[0023] (1) battery replacement starts;

[0024] (2) high-voltage disconnection check: the on-off of high-voltage electricity of the battery replacement module assembly is controlled through a key switch in the cab, and the on-off state of the high-voltage electricity is fed back through an indicator lamp arranged on the side surface of the battery replacement module assembly;

[0025] (3) unlocking of the power shortage battery replacement module assembly: the locking mechanism is operated to make the locking pin leave the locking pin working hole and the locking pin seat, and the unlocking state is fed back through the indicator lamp arranged on the side surface of the battery replacement module assembly;

[0026] (4) hoisting of the power shortage battery replacement module assembly;

[0027] (5) unloading of the power shortage battery replacement module assembly from the vehicle: the crane is operated to hoist the power shortage battery replacement module assembly from the vehicle to a designated place;

[0028] (6) hoisting of the full-power battery replacement module assembly;

[0029] (7) first stage of guidance: after confirming that the full-power battery replacement module assembly is effectively connected with the lifting tool, the crane is operated to hoist the full-power battery replacement module assembly into the installation area, and the bottom surface of the full-power battery replacement module assembly is slightly higher than the height of the rear guiding alignment structure, and then the full-power battery replacement module assembly is moved to the straight angle surface formed by the left guiding alignment structure and the front guiding alignment structure to be in contact with the straight angle surface;

[0030] (8) first stage of falling of the full-power battery replacement module assembly: after the full-power battery replacement module assembly completes the first stage of guidance alignment, the full-power battery replacement module assembly is slowly and orderly lowered under the driving of the crane;

[0031] (9) Secondary guiding stage: The three sides of the fully charged battery swapping module assembly are respectively attached to the rear guiding alignment structure, the left guiding alignment structure and the front guiding alignment structure;

[0032] (10) Second stage of the fully charged battery swapping module assembly falling: The fully charged battery swapping module assembly falls slowly and orderly under the joint restraint of the rear guide alignment structure, the left guide alignment structure and the front guide alignment structure;

[0033] (11) Positioning and alignment stage: The fully charged battery swapping module assembly is aligned by engaging with the guide groove and positioning pin hole on the front frame through the horizontal guide post, the vertical guide post and the positioning pin at the bottom;

[0034] (12) The third stage of the fully charged battery swapping module assembly is lowered: the fully charged battery swapping module assembly is lowered slowly and orderly during the positioning and alignment stage;

[0035] (13) Connector docking stage: The battery end connector and the vehicle end connector will automatically dock during the positioning and alignment process;

[0036] (14) The fourth stage of the fully charged battery swapping module assembly is lowered: it finally falls to the installation area set on the front frame of the battery swapping module assembly;

[0037] (15) Fully charged battery swapping module assembly hoisted into place: The top surface of the power battery box of the battery swapping module assembly is flush with the height of the cover in front of the mining truck;

[0038] (16) Connector mating status check: The connector mating status is determined by the indicator lights;

[0039] (17) Locking operation of the fully charged battery swapping module assembly: Operate the locking mechanism to insert the locking pin into the locking pin working hole and the locking pin seat, and judge the locking status by the indicator light;

[0040] (18) Battery swapping completed.

[0041] The beneficial effects of this invention compared to the prior art are:

[0042] 1) The battery swapping guide, positioning and locking structure adopts different clearance fit methods according to different matching requirements, so as to ensure the operability of installation while improving compatibility error;

[0043] 2) The battery swapping process adopts a three-level guidance system: the alignment structure is the primary guidance system, the guide column is the secondary guidance system, and the positioning pin is the tertiary guidance system. The accuracy of the guidance adjustment increases step by step, thereby improving the accuracy of battery swapping.

[0044] 3) During the battery swapping process, the electrical connection is automatically switched on and off by the connector, which is hoisted up and down with the battery swapping module assembly. No manual switching is required, which is simple and safe.

[0045] 4) The locking mechanism is safe and reliable, the components are easy to process, and it is operated by a handwheel. It converts rotational force into linear thrust, which is simple to operate. The use of a two-way thrust bearing isolates the operating lever from the locking pin, and only axial transmission is performed, which saves effort in operation.

[0046] 5) The locking mechanism is driven by a screw pair, which has a large propulsion force. After locking into place, it is self-locked by the thread, with a large locking force, and can be used in humid and vibrating environments;

[0047] 6) The locking status of the battery swapping module assembly can be monitored in real time through the instrument panel in the cab. A high-voltage on / off indicator light and a locking status indicator light are provided on the side of the battery swapping module assembly, making the visualization of the high-voltage on / off status and locking status more intuitive. Attached Figure Description

[0048] Figure 1 This is a schematic diagram showing the connection between the battery swapping module assembly and the front frame.

[0049] Figure 2 This is a schematic diagram showing the battery swapping module assembly disassembled from the front frame.

[0050] Figure 3 This is a schematic diagram of the bottom of the battery swapping module assembly.

[0051] Figure 4 A schematic diagram to guide the docking structure on the front frame.

[0052] Figure 5 This is a schematic diagram of the guide groove on the front frame.

[0053] Figure 6 This is a schematic diagram showing the locking mechanism working in conjunction with the front frame.

[0054] Figure 7 This is a schematic diagram of the locking mechanism's state.

[0055] Figure 8 This is a schematic diagram of the locking mechanism.

[0056] Figure 9 This is an exploded view of the locking pin.

[0057] Figure 10 This is a flowchart of the battery swapping process. Detailed Implementation

[0058] The present invention will now be further described with reference to the accompanying drawings.

[0059] like Figure 1 As shown, an underground trackless mining car battery swapping system includes a front frame 1, a battery swapping module assembly 2 located in the installation area of ​​the front frame 1, a guide mechanism for guiding the assembly and disassembly of the battery swapping module assembly 2, and a locking mechanism 3 for locking the battery swapping module assembly 2.

[0060] like Figure 1 As shown, the installation area is enclosed by a cover 4 located in front of the front frame 1, a cab 5 located on the left side of the front frame 1, and a front wheel mudguard. The right side of the installation area is unobstructed, and the battery swapping module assembly 2 has a similar shape to the side corresponding to the mudguard 6, making full use of the available space. The front frame 1 includes a base plate, a horizontally mounted mounting plate located above the base plate, and a support plate located between the base plate and the mounting plate. The base plate is slightly inclined upwards, and the base plate supports the mounting plate through the support plate. The battery swapping module assembly 2 sits on the mounting plate, ensuring the stability of the battery swapping module assembly 2 during installation.

[0061] like Figure 1 , 2 As shown, the battery swapping module assembly 2 includes a power battery housing 21, a power battery pack, a control housing 22, a high-voltage box, a power control box, a thermal management unit, and a thermal management expansion tank. The power battery housing 21 is rectangular in shape, and the power battery pack is stacked and arranged inside the power battery housing 21. Lifting lugs 211, which are hook-shaped, are provided at the four corners of the top of the power battery housing 21. The lifting lugs 211 cooperate with a lifting device, which is H-shaped and includes a crossbeam and booms at both ends of the crossbeam. The booms have protruding posts at both ends that cooperate with the lifting lugs. The control box 22 is located at the rear of the power battery box 21. The control box 22 is irregularly shaped, with its bottom surface higher than that of the power battery box 21. A clearance space is formed between the bottom surface of the control box 22 and the side surface of the power battery box 21. The top of the control box 22 is higher than that of the power battery box 21. Heat dissipation holes are also provided around the bottom of the control box 22. The high-voltage box, power control box, thermal management unit, and thermal management expansion tank are located inside the control box 22, forming an integrated module with the power battery for battery swapping. After battery swapping, the top surface of the power battery box 21 of the battery swapping module assembly 2 is flush with the top surface of the cover 4.

[0062] like Figure 2As shown, the battery swapping module assembly 2 achieves high-voltage electrical connection and low-voltage communication connection with the vehicle through two sets of self-aligning battery swapping connectors. The self-aligning battery swapping connectors include a vehicle-end connector 8 located on the front frame 1 and a battery-end connector 7 located on the battery swapping module assembly 2. The connectors themselves have a floating function, which can eliminate the error of docking adjustment during the battery swapping process and reduce the impact during docking. At the start of battery swapping, a high-voltage disconnection check must be performed. The high-voltage connection and disconnection are controlled by the key switch in the driver's cab 5, and the high-voltage connection and disconnection status is reflected by a red indicator light installed on the right side skin of the battery swapping module assembly 2. When the red indicator light on the right side of the battery swapping module assembly 2 is not lit, it indicates that the high-voltage connection of the battery swapping module assembly 2 has been disconnected, and the battery swapping operation can be performed; otherwise, the battery swapping operation cannot be performed. The battery connector 7 is located at the bottom of the control box 22, the vehicle connector 8 is located on the mounting bracket 9, the mounting bracket 9 is located on the front frame 1, and the mounting bracket 9 is located in the clearance space. The side of the battery swapping module assembly 2 is provided with a movable cover plate 221 corresponding to the clearance space position. When swapping batteries, the movable cover plate 221 can be opened to observe the docking status of the connector.

[0063] like Figures 3 to 5As shown, the guiding mechanism includes a transverse guide post 11, a longitudinal guide post 12, a positioning pin 13, a left-side guiding alignment structure 15, a rear-side guiding alignment structure 17, and a front-side guiding alignment structure 16. The transverse guide post 11, the longitudinal guide post 12, and the positioning pin 13 are located at the bottom of the battery swapping module assembly 2. The bottom surface of the battery swapping module assembly 2 mates with the mounting plate. The mounting plate has a positioning pin hole 18 that mates with the positioning pin 13. The front frame 1 has a guide groove 19 that mates with the transverse guide post 11 and the longitudinal guide post 12. By mates with the guide groove 19 on the front frame 1, the swinging motion of the battery swapping module assembly 2 is restricted while guiding the battery swapping module assembly 2 to be correctly installed in the corresponding position. A horizontal guide post 11 and a vertical guide post 12 form a set of guide components. The horizontal guide post 11 and the vertical guide post 12 are perpendicular to each other. The bottom of the power battery box 21 is provided with four sets of rectangularly distributed guide components. The horizontal guide post 11 and the vertical guide post 12 each include a vertical plate and a 45° inclined plate connected to the vertical plate. The guide groove 19 is provided with a wear-resistant limiting plate 191 that is attached to the vertical plate. The guide post first guides the alignment and then the positioning pin 13 accurately positions it. The left-side guide alignment structure 15 is mounted on the cab 5, the front-side guide alignment structure 16 is mounted on the front frame 1 and located in front of the installation area, and the rear-side guide alignment structure 17 is mounted on the front frame 1 and located behind the installation area. The left-side guide alignment structure 15, the rear-side guide alignment structure 17, and the front-side guide alignment structure 16 all include a column and a wedge at the top of the column. The left-side guide alignment structure 15 and the front-side guide alignment structure 16 are at the same height and higher than the rear-side guide alignment structure 17. The top wedge of the guide alignment structure has a 20° angle. As the battery swapping module assembly 2 enters the guide surface, the left and front guide alignment structures are relatively high, and the right angle formed by the two serves as the main alignment reference during hoisting. The rear guide alignment structure 17 is relatively low. After the battery swapping module assembly 2 has been aligned and lowered by the left and front first-level guides, the swing amplitude of the battery swapping module assembly 2 has been relatively reduced. The rear guide alignment structure 17, together with the left and front guide alignment structures 16, form a three-sided constraint, further reducing the swing amplitude of the battery swapping module assembly 2, and guiding the battery swapping module assembly 2 to prepare for the next stage of the guide stroke.

[0064] like Figure 3 As shown, the bottom of the battery swapping module assembly 2 is provided with a vibration damping pad 14 to isolate vibration and reduce its impact on the battery swapping module assembly 2 and its internal equipment. The sides of the battery swapping module assembly 2 are provided with buffer wear-resistant plates 10, specifically on the front, left, and rear sides, to meet the requirements of cooperating with the battery swapping structure of the front frame 1 during the battery swapping process and reduce the impact of collisions and friction on the battery swapping module assembly 2.

[0065] like Figures 6 to 9 As shown, the locking mechanism 3 includes a locking pin working hole on the support plate, a locking pin seat 31 at the bottom of the battery swapping module assembly 2, a locking pin 36 that mates with the locking pin working hole and the locking pin seat 31, a limit switch 37 for detecting the position of the locking pin 36, an operating rod 33 connected to the locking pin 36, a handwheel 35 that drives the operating rod 33 to rotate, and an operating rod seat 34. The front frame 1 is provided with a pin cylinder 32, which is welded to the bottom surface of the mounting plate. The pin cylinder is U-shaped, and the locking pin 36 passes through the pin cylinder 32. The side of the front frame 1 is provided with an operating compartment, and the operating rod seat 34 is located in the operating compartment. The operating rod 33 includes a rod and a sleeve fitted on the rod. The operating rod seat 34 includes a fixing plate and a cylindrical nut located in the middle of the fixing plate. The sleeve is inserted into the cylindrical nut and threadedly engaged with it. The front end of the operating lever is rotatably engaged with a locking pin. The front end of the operating lever is provided with a lever baffle 38, which is locked to the lever by an internal hexagonal screw. The locking pin 36 consists of a small-diameter section 361 and a large-diameter section 362. The end face of the large-diameter section 362 is provided with a groove 3621. A double-direction thrust bearing 39 is provided within the groove 3621, and the bearing is sealed within the groove 3621 by a pin cover plate 30. The front end of the operating lever 33 extends into the groove 3621, and the lever baffle 38 and the double-direction thrust bearing 39... To achieve a rotating connection, the locking pin 36 can extend and retract with the pushing and pulling of the operating lever 33, but is unaffected by the rotation of the operating lever 33. This reduces the force required by the operating lever 33 to control the locking pin 36, while also preventing the operating lever 33 from becoming stuck due to the locking pin 36, and reducing wear between the locking pin 36 and the pin cylinder 32. The small-diameter section 361 of the locking pin 36 is solid and is the working section that mates with the pin hole on the pin seat 31 at the bottom of the battery swapping module assembly 2. This embodiment has two sets of locking mechanisms 3, each corresponding to one of the two locking pin indicator lights on the outer side of the battery swapping module assembly 2. Two sets of locking mechanisms are used to meet the battery swapping locking requirements. The two sets of locking mechanisms are installed independently, distributing the working load and providing redundancy. Based on the installation position of the battery swapping module assembly 2, the two sets of locking mechanisms are arranged below the bottom plate of the battery swapping module assembly 2 mounting compartment, in the lateral direction of the vehicle, with the operating handwheel facing the right side of the vehicle for easy operation.

[0066] like Figure 10 As shown, the battery swapping method of the present invention includes the following steps:

[0067] (1) Battery swapping begins;

[0068] (2) High voltage disconnection check: The high voltage of the battery swapping module assembly is controlled by the key switch in the cab 5, and the high voltage status is fed back by the indicator light installed on the side of the battery swapping module assembly.

[0069] (3) Unlocking the battery swapping module assembly: Operate the locking mechanism to make the locking pin leave the locking pin working hole and locking pin seat 31, and use the indicator light installed on the side of the battery swapping module assembly to provide feedback on the unlocking status.

[0070] (4) Lifting of the battery swapping module assembly;

[0071] (5) Unloading the battery swapping module assembly: Use a crane to lift the battery swapping module assembly from the vehicle to the designated location;

[0072] (6) Lifting of the fully charged battery swapping module assembly;

[0073] (7) First-level guiding stage: After confirming that the fully charged battery swapping module assembly is effectively connected to the hoist, operate the crane to lift the fully charged battery swapping module assembly into the installation area, and make the bottom surface of the fully charged battery swapping module assembly slightly higher than the height of the rear guide alignment structure 17. Then, move the fully charged battery swapping module assembly closer to the right angle formed by the left guide alignment structure 15 and the front guide alignment structure 16 until they are in contact.

[0074] (8) The fully charged battery swapping module assembly falls in the first stage. After the fully charged battery swapping module assembly completes the first stage of guidance and alignment, it falls slowly and orderly under the drive of the crane.

[0075] (9) Secondary guiding stage: The three sides of the fully charged battery swapping module assembly are respectively attached to the rear guiding alignment structure 17, the left guiding alignment structure 15 and the front guiding alignment structure 16;

[0076] (10) Second stage of the fully charged battery swapping module assembly falling: The fully charged battery swapping module assembly falls slowly and orderly under the joint restraint of the rear guide alignment structure 17, the left guide alignment structure 15 and the front guide alignment structure 16;

[0077] (11) Positioning and alignment stage: The fully charged battery swapping module assembly is aligned by the horizontal guide post 11, the longitudinal guide post 12 and the positioning pin 13 at the bottom, respectively, in conjunction with the guide groove 19 and the positioning pin hole 18 on the front frame 1;

[0078] (12) The third stage of the fully charged battery swapping module assembly is lowered: the fully charged battery swapping module assembly is lowered slowly and orderly during the positioning and alignment stage;

[0079] (13) Connector docking stage: The battery end connector 7 and the vehicle end connector 8 of the connector will also automatically dock during the positioning and alignment process;

[0080] (14) The fourth stage of the fully charged battery swapping module assembly is lowered: it finally falls to the installation area set on the front frame 1 of the battery swapping module assembly;

[0081] (15) Fully charged battery swapping module assembly hoisted into place: The top surface of the power battery box 21 of the battery swapping module assembly is flush with the height of the cover 4 in front of the mining vehicle;

[0082] (16) Connector mating status check: The connector mating status is determined by the indicator lights;

[0083] (17) Locking operation of the fully charged battery swapping module assembly: Operate the locking mechanism to insert the locking pin into the locking pin working hole and the locking pin seat 31, and judge the locking status by the indicator light;

[0084] (18) Battery swapping completed.

Claims

1. A battery swapping system for underground trackless mining vehicles, characterized in that: It includes a front frame, a battery swapping module assembly located in the front frame mounting area, a guide mechanism for guiding the battery swapping module assembly during disassembly and assembly, and a locking mechanism for locking the battery swapping module assembly. The installation area is enclosed by a cover located in front of the front frame, a cab located on the left side of the front frame, and a front wheel mudguard. The front frame includes a floor plate, a mounting plate located above the floor plate and horizontally arranged, and a support plate located between the floor plate and the mounting plate. The battery swapping module assembly includes a power battery housing, a power battery pack, a control housing, a high-voltage box, a power control box, a thermal management unit, and a thermal management expansion tank. The power battery pack is housed inside the power battery housing, and the high-voltage box, power control box, thermal management unit, and thermal management expansion tank are housed inside the control housing. The control housing is located on one side of the power battery housing, and the top of the power battery housing is provided with lifting lugs. The battery swapping module assembly achieves high-voltage electrical connection and low-voltage communication connection with the vehicle through a self-aligning battery swapping connector. The self-aligning battery swapping connector includes a vehicle-end connector on the front frame and a battery-end connector on the battery swapping module assembly. The guiding mechanism includes a transverse guide post, a longitudinal guide post, a positioning pin, a left-side guiding alignment structure, a rear-side guiding alignment structure, and a front-side guiding alignment structure. The transverse guide post, longitudinal guide post, and positioning pin are located at the bottom of the battery swapping module assembly. The bottom surface of the battery swapping module assembly mates with the mounting plate. The mounting plate has positioning pin holes that mate with the positioning pins. The front frame has guide grooves that mate with the transverse and longitudinal guide posts. The left-side guiding alignment structure is located on the cab. The front-side guiding alignment structure is located on the front frame and in front of the installation area. The rear-side guiding alignment structure is located on the front frame and behind the installation area. The locking mechanism includes a locking pin working hole on the support plate, a locking pin seat at the bottom of the battery swapping module assembly, a locking pin that mates with the locking pin working hole and the locking pin seat, a limit switch for detecting the position of the locking pin, an operating rod connected to the locking pin, a handwheel that drives the operating rod to rotate, and an operating rod seat. The operating rod seat is fixed to the right side of the front frame, the operating rod is threaded into the operating rod seat, and the front end of the operating rod is rotatably engaged with the locking pin.

2. The battery swapping system for underground trackless mining cars according to claim 1, characterized in that: The top of the power battery box is provided with four rectangularly distributed lifting lugs. The lifting lugs cooperate with the lifting device, which is H-shaped and includes a crossbeam and booms at both ends of the crossbeam. The booms have protruding posts at both ends that cooperate with the lifting lugs.

3. The underground trackless mining car battery swapping system according to claim 1, characterized in that: The battery connector is located at the bottom of the control box, the vehicle connector is located on the mounting bracket, the mounting bracket is located on the front frame, a clearance space is formed between the bottom surface of the control box and the side surface of the power battery box, the mounting bracket is located within the clearance space, and a movable cover plate is provided on the side of the battery swapping module assembly corresponding to the clearance space.

4. The underground trackless mining car battery swapping system according to claim 1, characterized in that: The side of the control box is equipped with a charging socket, a high-voltage status indicator light, and a lock pin status indicator light.

5. The underground trackless mining car battery swapping system according to claim 1, characterized in that: A horizontal guide post and a vertical guide post constitute a set of guide components, and four sets of rectangularly distributed guide components are provided at the bottom of the power battery box.

6. The battery swapping system for underground trackless mining cars according to claim 1, characterized in that: The bottom of the battery swapping module assembly is provided with a vibration damping pad, and the sides of the battery swapping module assembly are provided with a buffer wear-resistant plate.

7. The underground trackless mining car battery swapping system according to claim 1, characterized in that: The left-side guide alignment structure, the rear-side guide alignment structure, and the front-side guide alignment structure all include a column and an inclined block at the upper end of the column. The left-side guide alignment structure and the front-side guide alignment structure are at the same height and are higher than the rear-side guide alignment structure. The transverse guide column and the longitudinal guide column all include a vertical plate and a 45° inclined plate connected to the vertical plate. The guide groove is provided with a wear-resistant limiting plate that is attached to the vertical plate.

8. The battery swapping system for underground trackless mining cars according to claim 1, characterized in that: The front frame has an operating compartment on its side, and the operating lever seat is located inside the operating compartment. The operating lever includes a rod and a sleeve fitted on the rod. The operating lever seat includes a fixing plate and a cylindrical nut located in the middle of the fixing plate. The sleeve is inserted into the cylindrical nut and is threaded into it.

9. The battery swapping system for underground trackless mining cars according to claim 1, characterized in that: The front frame is equipped with a pin cylinder, which is U-shaped, and the locking pin passes through the pin cylinder.

10. A battery swapping method for the underground trackless mining car battery swapping system as described in claim 1, characterized in that, Includes the following steps: (1) Battery swapping begins; (2) High voltage disconnection check: The high voltage of the battery swapping module assembly is controlled by the key switch in the cab, and the high voltage status is fed back by the indicator light installed on the side of the battery swapping module assembly. (3) Unlocking the battery swapping module assembly when the battery is low on power: Operate the locking mechanism to make the locking pin leave the locking pin working hole and the locking pin seat, and use the indicator light installed on the side of the battery swapping module assembly to provide feedback on the unlocking status. (4) Lifting of the battery swapping module assembly; (5) Unloading the battery swapping module assembly: Use a crane to lift the battery swapping module assembly from the vehicle to the designated location; (6) Lifting of the fully charged battery swapping module assembly; (7) First-level guiding stage: After confirming that the fully charged battery swapping module assembly is effectively connected to the hoist, operate the crane to lift the fully charged battery swapping module assembly into the installation area, and make the bottom surface of the fully charged battery swapping module assembly slightly higher than the height of the rear guide alignment structure. Then, move the fully charged battery swapping module assembly closer to the right angle formed by the left guide alignment structure and the front guide alignment structure until they are in contact. (8) The fully charged battery swapping module assembly falls in the first stage. After the fully charged battery swapping module assembly completes the first stage of guidance and alignment, it falls slowly and orderly under the drive of the crane. (9) Secondary guiding stage: The three sides of the fully charged battery swapping module assembly are respectively attached to the rear guiding alignment structure, the left guiding alignment structure and the front guiding alignment structure; (10) Second stage of the fully charged battery swapping module assembly falling: The fully charged battery swapping module assembly falls slowly and orderly under the joint restraint of the rear guide alignment structure, the left guide alignment structure and the front guide alignment structure; (11) Positioning and alignment stage: The fully charged battery swapping module assembly is aligned by engaging with the guide groove and positioning pin hole on the front frame through the horizontal guide post, the vertical guide post and the positioning pin at the bottom; (12) The third stage of the fully charged battery swapping module assembly is lowered: the fully charged battery swapping module assembly is lowered slowly and orderly during the positioning and alignment stage; (13) Connector docking stage: The battery end connector and the vehicle end connector will automatically dock during the positioning and alignment process; (14) The fourth stage of the fully charged battery swapping module assembly is lowered: it finally falls to the installation area set on the front frame of the battery swapping module assembly; (15) Fully charged battery swapping module assembly hoisted into place: The top surface of the power battery box of the battery swapping module assembly is flush with the height of the cover in front of the mining truck; (16) Connector mating status check: The connector mating status is determined by the indicator lights; (17) Locking operation of the fully charged battery swapping module assembly: Operate the locking mechanism to insert the locking pin into the locking pin working hole and the locking pin seat, and judge the locking status by the indicator light; (18) Battery swapping completed.

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