Battery type replacement method and mobile carrier

Abstract

The embodiment of the invention provides a battery type replacement method and a mobile carrier. The battery type replacement method comprises the following steps: arranging a second type of battery pack in a battery compartment of a primary battery type of the mobile carrier; based on the mass distribution parameters of the second type of battery pack and the gravity center stability requirement of the mobile carrier, determining the target mass and / or the installation position of a counterweight component, and arranging the counterweight component in a predefined counterweight installation area in the battery compartment; and in response to the operation state of the mobile carrier, adjusting the discharge voltage of the second type of battery pack to adapt to the input voltage requirement of the electric equipment in the mobile carrier through the voltage conversion unit at the original discharge interface, corresponding to the original battery pack, on the mobile carrier. The combination gravity center is adjusted by arranging the balance weight component, and the operation stability and safety of the movable carrier are guaranteed; the voltage conversion unit is used for adapting to the discharge voltage, normal work of electric equipment is ensured, large-scale transformation is avoided, and transformation cost and time cost are reduced.

Description

Technical Field

[0001] The present disclosure relates to the field of new energy application technology, and in particular to a battery type replacement method and a mobile vehicle. Background Art

[0002] With the development of new energy technologies, the demand for battery replacement in mobile vehicles is growing. Currently, replacing lead-acid batteries with lithium batteries is a common application scenario for mobile vehicle batteries. However, this process presents numerous technical challenges. Firstly, the shift in the mobile vehicle's center of gravity caused by battery replacement can severely impact its operational stability. Lead-acid and lithium batteries differ significantly in mass, volume, and mass distribution. For example, lead-acid batteries are often bulky, while lithium batteries are typically more compact and lighter. Direct replacement without adjusting the center of gravity can lead to safety hazards such as rollover and loss of control during driving, steering, and braking, seriously threatening operational safety and the safety of personnel, life, and property. Secondly, battery voltage adaptation presents a significant challenge. Lead-acid batteries have significantly different voltage output characteristics than lithium batteries. Their power supply relies on physical tapping and a fixed voltage output, while lithium batteries require voltage regulation via an intelligent voltage conversion unit. Continuing to use the existing discharge interface without targeted voltage conversion to adjust the lithium battery's discharge voltage will fail to meet the input voltage requirements of various electrical devices in the mobile vehicle, resulting in device malfunction or even damage. Summary of the Invention

[0003] In view of the above-mentioned shortcomings of the prior art, the purpose of the present disclosure is to provide a battery type replacement method and a mobile vehicle to solve the problems in the related art.

[0004] A first aspect of the present disclosure provides a battery type replacement method, which is applied to a mobile vehicle and includes:

[0005] Disposing a second type of battery pack in a battery compartment of the mobile vehicle of the original battery type;

[0006] Determining a target mass and / or installation position of a counterweight component based on the mass distribution parameters of the second-type battery pack and the center of gravity stability requirements of the mobile vehicle, and disposing a counterweight component in a predefined counterweight installation area within the battery compartment so that the combined center of gravity of the second-type battery pack and the counterweight component meets the dynamic stability requirements of the mobile vehicle;

[0007] In response to the operating status of the mobile vehicle, at the original discharge interface corresponding to the original battery pack on the mobile vehicle, the discharge voltage of the second type battery pack is adjusted by a voltage conversion unit to adapt to the input voltage requirements of the electrical equipment in the mobile vehicle.

[0008] In an embodiment of the first aspect, the weight balancing member includes at least one weight balancing member, which is detachably disposed on the top of the weight balancing member to adjust the weight of the weight balancing member and allow the weight balancing member to be suspended above the second type battery pack.

[0009] In an embodiment of the first aspect, a plurality of voltage conversion units are further included, each of which is provided corresponding to electrical devices with different supply voltage levels, and is used to convert the output voltage of the second type battery pack into a target voltage adapted to the input voltage range of the corresponding electrical devices.

[0010] In an embodiment of the first aspect, the primary battery type is a lead-acid battery; and / or the second-type battery pack is a lithium battery.

[0011] In an embodiment of the first aspect, the electrical device includes one or more of a controller, a sensor, a lighting system, and a speaker.

[0012] In an embodiment of the first aspect, it further includes: forming a new charging interface adapted to the second type of battery pack through an adapter at the original charging interface of the original battery type.

[0013] In an embodiment of the first aspect, the adapter includes a protocol conversion module for converting a communication protocol of the battery management system of the second type of battery pack into a communication protocol recognizable by the charging pile.

[0014] In an embodiment of the first aspect, before the second type battery pack is installed in the battery compartment, the method further includes:

[0015] Screening out a screened battery module that meets the replacement requirements from existing battery modules;

[0016] Obtaining the battery capacity of the screened battery modules, and dividing each of the screened battery modules into a plurality of capacity groups according to a preset battery capacity grading standard;

[0017] The screened battery modules in the same capacity group are connected in parallel to form the second type battery pack corresponding to the capacity group for replacement.

[0018] A second aspect of the present disclosure provides a mobile vehicle, in which any one of the above-mentioned battery type replacement methods is applied.

[0019] In an embodiment of the second aspect, the mobile vehicle comprises a forklift.

[0020] The beneficial effects of this disclosure are as follows: By providing a counterweight component to adjust the center of gravity of the assembly, this application ensures the operational stability and safety of the mobile vehicle; by utilizing a voltage conversion unit to adapt the discharge voltage, this ensures the normal operation of electrical equipment, avoids large-scale modifications, and reduces modification costs and time. Furthermore, it has good versatility and scalability, and can be adapted to a variety of vehicles and battery types, providing technical support for the promotion and application of green energy in the field of mobile vehicles and promoting industrial upgrading. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A schematic diagram showing the overall process of a battery type replacement method in one embodiment of the present disclosure is shown.

[0022] Figure 2 A schematic diagram showing the process of screening the second type of battery pack in the battery type replacement method in an embodiment of the present disclosure.

[0023] Figure 3 A schematic diagram of a battery compartment containing a second type of battery pack after modification in one embodiment of the present disclosure is shown.

[0024] Figure 4 A schematic diagram showing an embodiment of the present disclosure in which the original discharge interface is suitable for a second type of battery pack.

[0025] Figure 5 A schematic diagram showing the wiring of the original discharge interface suitable for a second type of battery pack in one embodiment of the present disclosure.

[0026] Figure 6 A schematic diagram showing charging between a second type battery pack and a charging pile in one embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0027] The following describes the embodiments of the present disclosure through specific examples. Those skilled in the art can easily understand the other advantages and effects of the present disclosure from the information disclosed in this disclosure. The present disclosure can also be implemented or applied through different specific embodiments. The details of the present disclosure can also be modified or changed according to different viewpoints and application modules without departing from the spirit of the present disclosure. It should be noted that the embodiments and features in the embodiments of the present disclosure can be combined with each other unless there is a conflict.

[0028] The following is a detailed description of the embodiments of the present disclosure with reference to the accompanying drawings so that those skilled in the art can easily implement the present disclosure. The present disclosure can be embodied in many different forms and is not limited to the embodiments described herein.

[0029] Throughout the present disclosure, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present disclosure. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or a group of embodiments or examples. Furthermore, those skilled in the art may combine and integrate different embodiments or examples, and features of different embodiments or examples, as described in the present disclosure, without conflicting requirements.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the context of this disclosure, "a group" means two or more, unless otherwise specifically defined.

[0031] In order to clearly describe the present disclosure, components not related to the description are omitted, and the same or similar components throughout the specification are denoted by the same reference numerals.

[0032] Throughout this specification, when a device is said to be "connected" to another device, this includes not only "direct connection" but also "indirect connection" with other elements interposed therebetween. Furthermore, when a device is said to "include" a certain component, unless otherwise stated, this does not exclude the inclusion of other components but rather implies that the device may include other components.

[0033] Although the terms first, second, etc. are used in this document to represent various elements in some examples, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, the first interface and the second interface, etc. are represented. Furthermore, as used in this document, the singular forms "one", "an", and "the" are intended to also include the plural forms, unless there is a contrary indication in the context. It should be further understood that the terms "comprise" and "include" indicate the presence of features, steps, operations, elements, modules, projects, types, and / or groups, but do not exclude the presence, occurrence, or addition of one or a group of other features, steps, operations, elements, modules, projects, types, and / or groups. The terms "or" and "and / or" used herein are interpreted as inclusive, or mean any one or any combination. Therefore, "A, B, or C" or "A, B, and / or C" means "any of the following: A; B; C; A and B; A and C; B and C; A, B, and C". Exceptions to this definition only occur when the combination of elements, functions, steps, or operations is inherently mutually exclusive in some way.

[0034] The technical terms used herein are intended only to refer to specific embodiments and are not intended to limit the present disclosure. The singular form used herein also includes the plural form unless the statement explicitly indicates otherwise. The term "comprising" as used in this specification is intended to specify specific features, regions, integers, steps, operations, elements, and / or components and does not exclude the presence or addition of other features, regions, integers, steps, operations, elements, and / or components.

[0035] Although not defined differently, all terms used herein, including technical and scientific terms, have the same meanings as those generally understood by those skilled in the art to which this disclosure belongs. Terms defined in commonly used dictionaries are additionally interpreted as having meanings consistent with relevant technical literature and the current message. Unless otherwise defined, they should not be overly interpreted as ideal or highly formalized meanings.

[0036] With the continuous development of new energy technologies, lithium batteries, due to their excellent electrochemical performance and environmentally friendly features, are gradually replacing traditional lead-acid batteries and becoming the preferred energy storage device for the power systems of various mobile vehicles (such as electric forklifts and logistics handling equipment). However, in many existing devices, the battery compartment structure, electrical system, and vehicle control system are designed based on the physical characteristics and electrical parameters of lead-acid batteries. Directly replacing them with lithium batteries often faces various adaptation issues.

[0037] First of all, there are significant differences between lead-acid batteries and lithium batteries in terms of mass distribution, external dimensions, energy density, etc. Direct replacement may cause the center of gravity of the entire vehicle to shift, affect operational stability, and even bring safety hazards.

[0038] Secondly, because lead-acid batteries are typically constructed from multiple 2V cells connected in series (for example, a 48V battery consists of 24 cells), it is possible to extract a portion of the cell voltage from the center of the battery pack to power low-voltage devices. For example, by selecting a specific combination of cells in an 80V lead-acid battery pack, a 48V voltage can be directly extracted to power low-voltage devices such as control systems and instruments. This approach leverages the independent tapping capabilities of lead-acid battery cells, eliminating the need for additional conversion equipment to meet different voltage requirements. However, lithium batteries differ from lead-acid batteries in their series-parallel structure and voltage output characteristics. Their cell voltage is higher (typically 3.2V or 3.7V), and for safety and lifespan management reasons, direct tapping from the center of the battery pack is generally not permitted. Therefore, when replacing lead-acid batteries with lithium batteries, the existing low-voltage device power supply method cannot be directly used, and additional voltage conversion mechanisms are required to meet the power requirements of devices at different voltage levels.

[0039] In order to solve the above problems, an embodiment of the present disclosure provides a battery type replacement method for a mobile vehicle.

[0040] With the continuous development of new energy technologies, lithium batteries, due to their excellent electrochemical performance and environmentally friendly properties, are gradually replacing traditional lead-acid batteries and becoming the preferred energy storage device for the power systems of various mobile vehicles (such as electric forklifts and logistics handling equipment). However, in many existing devices, the battery compartment (110) structure, electrical system, and vehicle control system are designed based on the physical properties and electrical parameters of lead-acid batteries. Directly replacing them with lithium batteries often faces various compatibility issues.

[0041] First of all, there are significant differences between lead-acid batteries and lithium batteries in terms of mass distribution, external dimensions, energy density, etc. Direct replacement may cause the center of gravity of the entire vehicle to shift, affect operational stability, and even bring safety hazards.

[0042] Secondly, because lead-acid batteries are typically constructed from multiple 2V cells connected in series (for example, a 48V battery consists of 24 cells), it is possible to extract a portion of the cell voltage from the center of the battery pack to power low-voltage devices. For example, by selecting a specific combination of cells in an 80V lead-acid battery pack, a 48V voltage can be directly extracted to power low-voltage devices such as control systems and instruments. This approach leverages the independent tapping capabilities of lead-acid battery cells, eliminating the need for additional conversion equipment to meet different voltage requirements. However, lithium batteries differ from lead-acid batteries in their series-parallel structure and voltage output characteristics. Their cell voltage is higher (typically 3.2V or 3.7V), and for safety and lifespan management reasons, direct tapping from the center of the battery pack is generally not permitted. Therefore, when replacing lead-acid batteries with lithium batteries, the existing low-voltage device power supply method cannot be directly used, and additional voltage conversion mechanisms are required to meet the power requirements of devices at different voltage levels.

[0043] In order to solve the above problems, an embodiment of the present disclosure provides a battery type replacement method, which is applied to a mobile vehicle 300; Figure 1 as well as Figure 2 In an embodiment, after a second type of battery pack 100 (such as a lithium battery) is installed in the original battery compartment 110 of a mobile vehicle 300, a detachable counterweight component 120 is set in a predefined area of ​​the battery compartment 110 based on its mass distribution parameters and the stability requirements of the vehicle's center of gravity. By adjusting the mass and installation position of the counterweight, the combined center of gravity of the battery pack and the counterweight meets the dynamic stability requirements of vehicles such as forklifts; at the same time, a voltage conversion unit 210 (such as a DC-DC converter 410) is integrated at the original discharge interface 200. When the vehicle is running, the unit converts the high voltage (such as 48V) of the lithium battery into a stable voltage of 12V / 24V for electrical equipment 310 such as adapter controllers and lighting systems.

[0044] exist Figure 1 In an embodiment, the battery replacement method includes:

[0045] Step S1: placing the second type battery pack 100 in the primary battery type battery compartment 110 of the mobile vehicle 300. Optionally, the mobile vehicle 300 includes a forklift.

[0046] The mobile vehicle 300 is an electric forklift. The lead-acid battery originally used as the power source now needs to be replaced with a lithium-ion battery with higher energy density and longer cycle life. First, the original lead-acid battery is powered off and safely removed, and the internal space of the battery compartment 110 is cleaned; then the battery compartment 110 is checked for compatibility to confirm that the volume of the new battery is compatible with the structure of the original battery compartment 110; then the lithium-ion battery pack is placed steadily in the battery compartment 110. Through the implementation of the above step S1, without changing the overall structure of the forklift, the lead-acid battery is successfully replaced with a lithium-ion battery, which improves the endurance and energy efficiency performance. At the same time, the original battery compartment 110 design is retained, reducing the cost of modification and engineering complexity, and providing a good foundation for subsequent center of gravity adjustment and voltage adaptation.

[0047] Optionally, in Figure 2 In an embodiment, before the second type battery pack 100 is installed in the battery compartment 110 , the method further includes:

[0048] Step S11: selecting the selected battery modules that meet the replacement requirements from the existing battery modules.

[0049] Optionally, the replacement requirement includes at least one of the following:

[0050] 1) The capacity retention rate of the battery module meets the preset retention range.

[0051] The capacity retention rate refers to the ratio of the actual available capacity of the current battery to the nominal capacity (i.e., the rated capacity at the time of shipment). For example, if the preset retention range is set to 80% to 95%, only those battery modules whose actual capacity still remains between 80% and 95% of their nominal capacity are considered eligible for replacement.

[0052] 2) The internal resistance of the battery module does not exceed a preset multiple of its factory-calibrated internal resistance.

[0053] The internal resistance value of the battery module shall not exceed the preset multiple of its factory-calibrated internal resistance value. The internal resistance value is an important parameter to measure the internal resistance of the battery, which directly affects the working efficiency and heat generation of the battery. Normally, the internal resistance of the battery will gradually increase with the increase of usage time. In order to ensure the safety and efficiency of the battery, a reasonable preset multiple can be set as a screening criterion. For example, if the preset multiple is set to 1.5 times, only battery modules whose current internal resistance does not exceed 1.5 times the factory-calibrated internal resistance value can be selected for replacement.

[0054] Through the above screening conditions, a battery module with stable performance, safety and reliability can be selected from the existing battery modules to ensure that the final second type battery pack 100 has good consistency, reliability and safety, while extending its service life and improving resource utilization.

[0055] Further, step S12: obtaining the battery capacity of the screened battery modules, and dividing each of the screened battery modules into a plurality of capacity groups according to a preset battery capacity grading standard.

[0056] Specifically, the grading standards can be customized according to specific application requirements, but the following aspects are generally considered. Capacity range: For example, Class A can be set as a capacity greater than or equal to 90% of the nominal capacity, Class B as 80%~90%, Class C as 70% to 80%, and so on. The specific grading boundaries should be determined according to the needs of the actual application scenario. Or purpose of use: Different applications may have different requirements for the capacity of the battery pack. For example, high-power output scenarios may prefer to choose battery modules with higher capacity and good consistency, while energy storage systems may pay more attention to cost-effectiveness and allow battery modules with large capacity differences within a certain range to be used in parallel.

[0057] In some embodiments, taking into account the working characteristics of electric forklifts, such as frequent starting, acceleration, braking, and carrying heavy objects, higher requirements are placed on the stability and consistency of the battery system. Based on this, the capacity of the screened battery modules can be graded according to the following principles: High-capacity group: suitable for forklifts that require long-term continuous operation or are used under heavy load conditions, ensuring sufficient endurance even under high-load conditions. Medium-capacity group: suitable for routine handling tasks in daily warehouse management. This type of forklift usually does not require extremely high power output, but requires good economy and a long service life. Low-capacity group: can be used in light-duty working environments or as a backup power source. Although the battery life after a single charge is short, it is an economical choice for occasional use.

[0058] Finally, step S13: connecting the screened battery modules in the same capacity group in parallel to form the second-type battery pack 100 corresponding to the capacity group for replacement.

[0059] Specifically, when battery modules are connected in parallel, this means that the current will be distributed according to the internal resistance and capacity characteristics of each module. If the capacity difference between the modules is too large, some modules may cause excessive current to be carried during the charging and discharging process, increasing the risk of overheating or damage. By selecting modules of the same capacity group for parallel connection, this situation can be effectively avoided, so that the current is more evenly distributed among the modules. Parallel connection increases the total capacity of the entire battery system, which means longer operating time and higher work efficiency in application scenarios such as electric forklifts. Due to the high consistency between the modules, parallel use helps to slow down the premature aging of individual modules due to overuse, thereby extending the service life of the entire battery system.

[0060] Different types of batteries (for example, switching from lead-acid batteries to lithium-ion batteries) can have significant differences in mass and volume. Even if the new battery has a higher energy density and is lighter, this change in mass can cause the center of gravity of the vehicle to shift. If not properly adjusted, this can affect the balance of the vehicle, especially when driving at high speeds, making sharp turns, or carrying heavy objects. Therefore, Figure 1 In step S2 of the embodiment: based on the mass distribution parameters of the second-type battery pack 100 and the center of gravity stability requirements of the mobile vehicle 300, the target mass and / or installation position of the counterweight component 120 is determined, and a counterweight component 120 is set in a predefined counterweight installation area in the battery compartment 110 so that the combined center of gravity of the second-type battery pack and the counterweight component 120 meets the dynamic stability requirements of the mobile vehicle 300.

[0061] Please refer to Figure 3 In an embodiment, the counterweight member 120 can be implemented as an integrated position-limiting and counterweight structure. This structure includes a position-limiting frame of predetermined mass, made of cast iron or high-strength steel, and positioned within a predetermined area within the battery compartment 110. The position-limiting frame not only defines the installation position of the second-type battery pack 100, preventing displacement during operation, but also contributes to the vehicle's center of gravity through its own mass.

[0062] In actual applications, users can select different mass levels of restraining frames as the counterweight components 120 based on the mass differences of the selected second-type battery packs 100. For example, when using lightweight batteries, a restraining frame with a higher mass can be selected; when using high-capacity, high-mass batteries, a restraining frame with a lower mass can be selected or some counterweight modules can be omitted, thereby achieving flexible control of the center of gravity of the entire vehicle.

[0063] In another embodiment, optionally, the weight balancing member 120 includes at least one weight balancing member, which is detachably provided on the top of the weight balancing member 120 for adjusting the weight of the weight balancing member 120 and allowing the weight balancing member to be suspended above the second type battery pack 100.

[0064] Specifically, each counterweight is made of a high-density material, such as metal, tungsten alloy or high-density composite material, to ensure a larger mass in a smaller volume. The counterweight is connected to the counterweight member 120 by snaps, threaded connections or other convenient fixing methods, which is convenient for quick loading and unloading. Since the counterweight is detachable, the user can increase or decrease the number of counterweights according to actual needs to fine-tune the total weight of the entire counterweight assembly. This method allows the center of gravity of the entire vehicle to be precisely adjusted to accommodate battery packs of different capacities and weights.

[0065] In some embodiments, the counterweight is positioned and matched with at least one of the counterweight components 120 .

[0066] In some embodiments, the counterweight piece and at least one of the counterweight components 120 are matched in a concave-convex manner.

[0067] In some embodiments, the counterweight is fitted into at least one of the counterweight components 120 .

[0068] Optionally, the primary battery is a lead-acid battery. Optionally, the second type battery pack 100 is a lithium battery.

[0069] Specifically, in the battery replacement solution for the mobile vehicle 300, the original battery type can be lead-acid, nickel-cadmium, or nickel-metal hydride. For example, a traditional electric vehicle may initially be equipped with lead-acid batteries, which are low-cost but have low energy density and are heavy. As technology advances, these batteries can be replaced with lithium batteries or lithium iron phosphate (LiFePO4) batteries to increase energy density and range, while reducing vehicle weight and improving charging efficiency. Similarly, if the original battery type is nickel-cadmium, replacing it with a lithium battery is a viable option for environmental and performance reasons. This not only eliminates the memory effect but also increases energy density and service life. For devices using nickel-metal hydride batteries, upgrading to lithium batteries can further reduce self-discharge, extend service life, and improve overall performance. By switching between these different battery types, the performance of the mobile vehicle 300, such as range, safety, and environmental friendliness, can be optimized according to specific needs, while ensuring that the combination of the second-type battery pack and the counterweight member 120 meets the dynamic stability requirements of the vehicle, ensuring safe and stable operation.

[0070] Step S3: In response to the operating status of the mobile vehicle 300, at the original discharge interface 200 corresponding to the original battery pack on the mobile vehicle 300, the discharge voltage of the second type battery pack 100 is adjusted through the voltage conversion unit 210 to adapt to the input voltage requirement of the electrical equipment 310 in the mobile vehicle 300.

[0071] Specifically, in Figure 4 In an embodiment, a voltage conversion unit 210 is provided at the original discharge interface 200 of the original battery pack on the mobile vehicle 300, which is used to dynamically adjust the output voltage of the second type battery pack 100 according to the operating status so that it complies with the input voltage range supported by the vehicle electrical equipment 310 (such as a controller, a drive motor, a lighting system, etc.).

[0072] The main purpose of setting up the voltage conversion unit 210 is to solve the voltage mismatch problem that may occur when replacing the lead-acid battery with a lithium battery, and to ensure the compatibility of the second type battery pack with the original electrical system of the mobile vehicle 300. Since the nominal voltage and operating voltage range of lithium batteries are usually different from those of lead-acid batteries, for example, the original system is designed to adapt to 48V lead-acid batteries, and the replaced lithium battery pack may be 51.2V or 60V, direct connection may cause the electrical equipment 310 (such as controllers, drive motors, etc.) to malfunction or even be damaged due to overvoltage or undervoltage. Therefore, the voltage conversion unit 210 is set at the original discharge interface 200 of the original battery pack, which can dynamically adjust the output voltage of the second type battery pack 100 to be within the input voltage range that adapts to the original equipment, thereby ensuring the stable operation of the system. The voltage conversion unit 210 is usually a DC-DC converter with a wide input voltage range and stable output regulation capabilities.

[0073] Optional, please refer to Figure 5 In one embodiment, a split line is created at the original discharge port, with one line connected directly to the charging port of the mobile vehicle for charging; another line is connected to the input of a voltage conversion unit, and the output of the voltage conversion unit is then connected to the electrical devices on the mobile vehicle that require power. In some embodiments, to ensure safety and proper operation, a corresponding switch or fuse can be installed at the split line to disconnect the circuit when necessary to prevent overload or short circuit.

[0074] Furthermore, the voltage conversion unit 210 can intelligently adjust itself based on the operating state of the mobile vehicle 300. For example, it can automatically improve output stability under high load conditions to ensure power performance, and limit output power under low battery or temperature conditions to protect battery safety. Some advanced voltage converters 410 also integrate communication interfaces that allow them to interact with the vehicle control system (BMS or VCU) and provide real-time feedback on voltage, current, temperature, and other information, further enhancing system safety and controllability.

[0075] The voltage conversion unit 210 achieves voltage conversion through power electronics technology. Its core approach is to use switching elements (such as MOSFETs or IGBTs) and energy storage elements (such as inductors and capacitors) to precisely control the input voltage and output the desired stable voltage. Taking the buck converter 410 as an example, when the switch is on, current flows from the input power source through the inductor to the load, charging the capacitor. When the switch is off, the inductor continues to supply power to the load through the diode, releasing previously stored energy and maintaining a stable output voltage. The output voltage is regulated by adjusting the duty cycle of the switching element to ensure it meets the set value.

[0076] Optionally, multiple voltage conversion units 210 are respectively provided corresponding to electrical devices 310 with different supply voltage levels, and are used to convert the output voltage of the second-type battery pack 100 into a target voltage adapted to the input voltage range of the corresponding electrical devices 310.

[0077] Specifically, to better adapt to different power supply voltage levels of electrical devices 310, multiple voltage conversion units 210 can be provided. For example, corresponding DC-DC converters 410 can be configured for different load requirements, such as a 12V control module, a 24V auxiliary system, or a 48V drive motor, to achieve precise voltage matching.

[0078] For low-voltage devices (such as 12V instrument panels and lighting systems), a dedicated buck converter 410 may be provided to reduce the higher output voltage (eg, 51.2V or 60V) of the second type battery pack 100 to the required 12V.

[0079] For high-voltage devices (such as a 48V drive motor), another voltage conversion unit 210 can be used to ensure that it can obtain a close operating voltage directly from the battery pack and perform fine-tuning when necessary to achieve optimal performance.

[0080] If there are devices with intermediate voltage levels (such as a 24V auxiliary system), they are also equipped with corresponding voltage conversion units 210 to achieve accurate voltage matching.

[0081] Optionally, the electrical device 310 includes one or more of a controller, a sensor, a lighting system, and a speaker.

[0082] Specifically, in the operation and performance of a forklift, electrical devices 310, such as the controller, sensors, lighting system, and horn, each play an indispensable role. The controller, as the core control center, is responsible for receiving operational commands and precisely controlling the forklift's speed, steering, and fork lift functions. Sensors monitor key forklift parameters, such as battery level, temperature, and speed, in real time, and prevent collisions and cargo overturning through status monitoring and safety features. The lighting system not only improves visibility in low-light environments, ensuring a clear field of view for the driver, but also communicates the forklift's motion status to surrounding areas through warning lights, enhancing operational safety and meeting regulatory requirements. The horn acts as an audible warning device, sounding an alarm when approaching pedestrians or other vehicles, prompting them to steer clear. It also serves as an effective communication tool in noisy environments, ensuring compliance with safety regulations. Therefore, ensuring that these devices receive a stable and adequate power supply even after battery type changes is crucial. By providing multiple voltage conversion units 210 to accommodate the needs of different electrical devices 310, voltage mismatches can be effectively addressed, ensuring the efficient and safe operation of the forklift system.

[0083] Optionally, in Figure 6 In an embodiment, the battery type replacement method further includes: forming a new charging interface adapted to the second type battery pack 100 through an adapter at the original charging interface of the original battery type.

[0084] Specifically, lead-acid batteries and lithium batteries typically use different charging interface designs. For example, lead-acid batteries may use a specific type of plug or socket, while lithium batteries use a standard plug or socket with certain differences. This physical incompatibility makes direct replacement not feasible. Secondly, the standard voltage of lead-acid batteries is different from that of lithium batteries. Direct connection may result in insufficient or overcharging, affecting battery performance and even posing a safety hazard. Many lead-acid battery systems lack the ability to communicate with the vehicle management system (BMS), and lithium batteries usually need to transmit key parameters (such as remaining charge SOC, health status SOH, temperature, etc.) through communication pins to ensure safe and efficient operation. Even if both support some form of communication, the data format and communication protocol they use may be completely different. This means that even if the physical connection is possible, effective data exchange cannot be achieved. To solve the above problems, refer to Figure 6 In the embodiment, a converter 410 is added between the second type battery pack 100 and the original charging port 400 to form a new charging interface. The converter 410 can convert the original charging port 400 into a new charging port 401 suitable for the second type battery pack 100, solving the problem of physical connection.

[0085] In some embodiments, the converter 410 integrates a voltage regulation circuit to ensure correct charging voltage and current, protecting the lithium battery from improper charging. This eliminates the need to replace existing charging infrastructure, reducing upgrade costs.

[0086] In the process of upgrading from lead-acid batteries to lithium-ion batteries, in addition to addressing electrical characteristics such as voltage and current, it is also necessary to resolve the issue of incompatible communication protocols between the two. Optionally, the converter 410 includes a protocol conversion module for converting the communication protocol of the lithium-ion battery's battery management system into a communication protocol recognizable by the charging station.

[0087] Specifically, the charging process for traditional lead-acid batteries is relatively simple, requiring no complex management and monitoring mechanisms like those for lithium-ion batteries. Lead-acid batteries typically utilize a constant current-constant voltage (CC-CV) charging mode, which is relatively straightforward and does not involve complex charge stage management. Compared to lithium-ion batteries, lead-acid batteries have a certain tolerance for slight overcharging. While long-term overcharging can still cause damage or shorten battery life, the short-term impact is less severe. However, when replacing lead-acid batteries with lithium-ion batteries, the situation becomes significantly more complex, as lithium-ion batteries have more stringent safety and performance requirements. Lithium-ion batteries require precise charging control, including multiple stages such as pre-charge, constant current charging, and constant voltage charging, each with specific requirements. Without proper charging management, battery damage and even safety incidents can occur. A lithium-ion battery battery management system (BMS) must continuously monitor battery status parameters (such as state of charge (SOC), state of hydration (SOH), and temperature) and dynamically adjust charging strategies based on this data. This requires the charging system to receive and respond to information from the BMS. During the replacement process with lithium-ion batteries, despite the many advantages of lithium-ion batteries, the existing charging system is often designed based on the characteristics of lead-acid batteries. This means they may not be directly compatible with lithium-ion batteries and their battery management systems (BMS). To ensure seamless integration between new and existing systems and fully leverage the advantages of lithium-ion batteries, a protocol conversion module is necessary. This module enables precise charging management of lithium-ion batteries, preventing overcharging, over-discharging, overheating, and other conditions that could damage the battery. This not only ensures safe operation of the equipment but also extends the battery life. With the protocol conversion module, existing charging stations 500 and vehicle control systems can support the new lithium-ion battery system without requiring major modifications. This significantly reduces upgrade costs and technical complexity, making the transition from lead-acid batteries to lithium-ion batteries smoother.

[0088] In yet another embodiment of the present disclosure, a mobile vehicle is provided, wherein the battery type replacement method described in any one of the above embodiments is applied.

[0089] The above embodiments are merely illustrative of the principles and effects of this disclosure and are not intended to limit this disclosure. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of this disclosure. Therefore, any equivalent modifications or alterations made by a person skilled in the art without departing from the spirit and technical concepts disclosed herein shall be encompassed by the scope of protection of this disclosure.

Claims

1. A method for replacing battery type, characterized in that: Applicable to mobile vehicles; including: Disposing a second type of battery pack in a battery compartment of the mobile vehicle of the original battery type; Determining a target mass and / or installation position of a counterweight component based on the mass distribution parameters of the second-type battery pack and the center of gravity stability requirements of the mobile vehicle, and disposing a counterweight component in a predefined counterweight installation area within the battery compartment so that the combined center of gravity of the second-type battery pack and the counterweight component meets the dynamic stability requirements of the mobile vehicle; In response to the operating status of the mobile vehicle, at the original discharge interface corresponding to the original battery pack on the mobile vehicle, the discharge voltage of the second type battery pack is adjusted by at least one voltage conversion unit to adapt to the input voltage requirement of the electrical equipment in the mobile vehicle.

2. The battery type replacement method according to claim 1, characterized in that: The weight component includes at least one weight component, which is detachably disposed on the top of the weight component for adjusting the weight of the weight component and allowing the weight component to be suspended above the second type battery pack.

3. The battery type replacement method according to claim 1, characterized in that: It also includes multiple voltage conversion units, which are respectively set corresponding to electrical devices with different supply voltage levels, and are used to convert the output voltage of the second type battery pack into a target voltage that is adapted to the input voltage range of the corresponding electrical devices.

4. The battery type replacement method according to claim 1, characterized in that: The primary battery type is a lead-acid battery; and / or the second type battery pack is a lithium battery.

5. The battery type replacement method according to claim 1, characterized in that: The electrical equipment includes one or more of a controller, a sensor, a lighting system, and a speaker.

6. The battery type replacement method according to claim 1, characterized in that: Also includes: The original charging interface of the original battery type is converted into a new charging interface adapted to the second type battery pack through an adapter.

7. The battery type replacement method according to claim 6, characterized in that: The adapter includes a protocol conversion module for converting the communication protocol of the battery management system of the second type of battery pack into a communication protocol recognizable by the charging pile.

8. The battery type replacement method according to claim 1, characterized in that: Before the second type battery pack is installed in the battery compartment, the method further includes: Screening out a screened battery module that meets the replacement requirements from existing battery modules; Obtaining the battery capacity of the screened battery modules, and dividing each of the screened battery modules into a plurality of capacity groups according to a preset battery capacity grading standard; The screened battery modules in the same capacity group are connected in parallel to form the second type battery pack corresponding to the capacity group for replacement.

9. A mobile vehicle, characterized in that: The battery type replacement method according to any one of claims 1 to 8 is applied.

10. The mobile vehicle according to claim 9, characterized in that: The mobile vehicle includes a forklift.

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