Battery replacement system of high-voltage lithium battery counterbalance forklift truck

Abstract

The invention discloses a high-voltage lithium battery counterbalance forklift battery replacing system which is characterized in that a split type high-voltage battery system is arranged in a forklift body of a battery replacing forklift, and the split type high-voltage battery system supplies power to the forklift body of the battery replacing forklift; the explosion-proof box type battery swapping station has the functions of battery swapping, charging and distribution, and a battery swapping forklift user selects to autonomously go to the battery swapping station for battery swapping or applies for distribution and battery swapping on the cloud management platform; the battery swap dispatching cloud management platform performs special management on the battery swap forklifts and the explosion-proof box type battery swap stations of different clients; the requirements of small and medium-sized battery replacing forklift clients are met, for small and medium-sized clients without capital construction conditions, the prefabricated explosion-proof box type battery replacing station can meet the requirements of battery charging and replacing and can also meet the safety requirement, and the problem that the small and medium-sized clients build the battery charging and replacing station at low cost is solved; the forklift and the battery are dispatched and remotely monitored through the battery replacement dispatching cloud management platform, the battery is maintained and managed, and the technical problems in the aspects of customer dispatching management and the like are solved.

Description

Technical Field

[0001] The present invention relates to the field of high-voltage battery-swap forklifts, and in particular to a battery-swap system for high-voltage lithium-ion counterbalanced forklifts. Background Art

[0002] Rapid battery replacement enables 24-hour uninterrupted operation, meeting the continuous operation needs of enterprises. Battery replacement for high-voltage lithium-ion forklifts used in heavy-duty, outdoor environments and complex working conditions is in its early stages, making manual battery replacement systems the best choice for small and medium-sized customers.

[0003] Currently, all low-voltage lithium-ion forklifts below 150V on the market are manually replaced with batteries, which use the battery replacement plug-in and form of lead-acid batteries; for high-voltage lithium-ion forklifts above 150V used for outdoor heavy loads and complex working conditions, there is only one model on the market that uses the high-voltage battery of a light truck for automatic battery replacement and requires a robotic arm to replace the battery. The battery replacement equipment requires an investment of about 2 million yuan. The large initial investment is not suitable for small and medium-sized battery replacement forklift customers. There is an urgent need for a high-voltage lithium-ion forklift that can be manually replaced to meet the needs of small and medium-sized customers. Summary of the Invention

[0004] In response to the problems existing in the above-mentioned prior art, the present invention provides a high-voltage lithium-ion counterbalanced forklift battery replacement system to meet the needs of small and medium-sized battery replacement forklift customers. For small and medium-sized customers without infrastructure conditions, prefabricated explosion-proof box-type battery replacement stations can meet both the charging and battery replacement requirements and the safety requirements, solving the problem of low-cost construction of charging and battery replacement stations for small and medium-sized customers; through the battery replacement scheduling cloud management platform, forklifts and batteries are dispatched and remotely monitored, and batteries are maintained and managed, solving technical problems in customer scheduling and management.

[0005] In order to achieve the above objectives, the technical solution adopted by the present invention is: a high-voltage lithium-ion counterbalanced forklift battery replacement system, comprising: The battery-swap forklift is equipped with a split high-voltage battery system inside the body, which supplies power to the body of the battery-swap forklift; The explosion-proof box-type battery swap station has the functions of battery swapping, charging and delivery. Battery swap forklift users can choose to swap batteries at the station or apply for delivery and battery swapping on the cloud management platform. The battery swap dispatch cloud management platform provides special management for different customers' battery swap forklifts and explosion-proof box-type battery swap stations.

[0006] Furthermore, the split high-voltage battery system includes: a battery pack, a battery swap plug-in and wiring harness, and a junction box. The junction box is connected to the battery pack through the battery swap plug-in and wiring harness. The battery swap plug-in is a snap-on battery swap plug-in, including a battery swap plug and a battery swap socket. It is fixed by connecting the plug-in assistant buckle on the battery swap plug with the card head on the battery swap socket. The battery swap socket is set on the battery pack, and the battery swap plug is connected to the wiring harness.

[0007] Furthermore, the battery pack: battery module, internal wiring harness and control assembly. The battery pack is arranged in layers to improve space utilization. A slot is designed at the bottom of the battery pack for forklift replacement of batteries. The internal wiring harness is used for power transmission and battery cell voltage and temperature collection. The control assembly consists of a BMS control system, relays and control wiring harness, which can control the on and off of the power electricity and is also responsible for data monitoring and storage. The BMS in the control assembly has remote monitoring and data storage functions.

[0008] Furthermore, the battery swap plug-in is equipped with one DC high voltage port, one grounding port, one DC output port, communication, monitoring and low voltage interfaces.

[0009] Furthermore, one DC high voltage: one interface each for total positive and total negative, with a rated current of not less than 250A and a withstand voltage of not less than 1000VDC; one DC output port: total positive and total negative, with a rated current of not less than 30A and a withstand voltage of not less than 1000VDC.

[0010] Furthermore, the explosion-proof box-type battery swap station includes a container, a one-to-five charging pile, a thermal management system, a ventilation and exhaust system, an automatic fire-fighting alarm system and a lighting system. The one-to-five charging pile, the thermal management system, the ventilation and exhaust system, the automatic fire-fighting alarm system and the lighting system are arranged in the container, among which there are multiple one-to-five charging piles.

[0011] Furthermore, the thermal management system includes an air-conditioning system and a water circulation system. The air-conditioning system of the battery swap station is automatically adjusted according to the temperature of the battery. Water cooling and water heating can be performed according to the temperature of the battery to enable the battery to be charged and stored at a suitable temperature, thereby increasing the battery life and reducing the cost of use.

[0012] Furthermore, the automatic fire extinguishing alarm system is used to monitor the temperature of batteries and containers, and through the coordinated work of sensors, control devices and fire extinguishing equipment, it is an intelligent fire-fighting facility that automatically detects, alarms and implements fire extinguishing when a fire occurs.

[0013] Furthermore, the battery swap scheduling cloud management platform includes: a charging and swapping WeChat applet and an online battery swap scheduling management cloud platform, and the online battery swap scheduling management cloud platform is accessed through the charging and swapping WeChat applet.

[0014] A high-voltage lithium-ion counterbalanced forklift battery replacement system, and its operation method: Forklift drivers can choose to go to a battery swap station to swap batteries on their own, or they can submit a battery swap application on the cloud management platform. After scheduling through the platform, the battery swap station will deliver and swap batteries. After the swap, the replaced batteries will be transported back to the battery swap station for charging. The online battery swap scheduling management cloud platform establishes sub-accounts to specifically manage the battery swap forklifts and battery swap stations of different customers; the battery and vehicle data of the battery swap forklift are uploaded to the online battery swap scheduling management cloud platform in real time, the real-time position of the battery swap forklift and battery is located, and the battery swap scheduling management is carried out for the battery swap forklift; the battery is statistically analyzed and balanced through the online battery swap scheduling management cloud platform in the background. The online battery swap scheduling management cloud platform solves the market problem that forklifts and batteries cannot be monitored synchronously.

[0015] The beneficial effects of the present invention are: the high-voltage lithium-ion counterbalanced forklift battery replacement system meets the needs of small and medium-sized battery replacement forklift customers. For small and medium-sized customers without infrastructure conditions, the prefabricated explosion-proof box-type battery replacement station can meet both the charging and battery replacement requirements and the safety requirements, solving the problem of low-cost construction of charging and battery replacement stations for small and medium-sized customers; through the battery replacement scheduling cloud management platform, forklifts and batteries are dispatched and remotely monitored, and batteries are maintained and managed, solving technical problems in customer scheduling and management. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the system structure of the present invention; Figure 2 This is a structural diagram of a battery-swap forklift; Figure 3 It is a structural diagram of a split high-voltage battery system; Figure 4 This is a schematic diagram of the structure of the battery swap plug-in; Figure 5 This is a structural diagram of an explosion-proof box-type battery swap station; Figure 6 This is a schematic diagram of the battery swap scheduling cloud management platform; Figure 7 This is a schematic diagram of the battery swap scheduling cloud management platform; In the figure: 1. Battery-swapping forklift; 11. Vehicle body; 12. Battery compartment door; 13. Split high-voltage battery system; 14. Battery pack; 15. Battery-swapping plug-in; 151. Battery-swapping plug; 152. Battery-swapping socket; 153. Plug-in assistant buckle; 16. Wiring harness; 17. Junction box; 2. Explosion-proof box-type battery-swapping station; 21. One-to-five charging pile; 3. Battery-swapping scheduling cloud management platform. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are only used to illustrate the present invention and are not intended to limit the scope of the present invention.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present invention pertains. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0019] like Figure 1 As shown, a high-voltage lithium-ion counterbalanced forklift battery replacement system includes: A split high-voltage battery system 13 is provided inside the body 11 of the battery-swapping forklift 1 , and the split high-voltage battery system 13 supplies power to the body 11 of the battery-swapping forklift 1 ; The explosion-proof box-type battery swap station 2 has the functions of battery swapping, charging and delivery. The user of the battery swap forklift 1 can choose to swap batteries at the battery swap station or apply for delivery and battery swapping on the cloud management platform; The battery swap dispatch cloud management platform 3 performs special management of battery swap forklifts 1 and explosion-proof box-type battery swap stations 2 for different customers.

[0020] The battery-swapping forklift 1, the explosion-proof box-type battery swap station 2 and the battery-swapping dispatch cloud management platform 3 are interrelated and dependent on each other. The product used by the customer is a lithium-ion forklift, which is powered by a lithium battery. The battery life of the lithium battery is a pain point for continuous operation. Battery swapping can quickly solve the battery life problem. The core of forklift battery swapping is the battery swap network, that is, the construction of battery swap stations and battery swap management platforms. The prefabricated battery swap stations, forklifts and management platforms constitute a battery swap system. Users can meet the needs of continuous operation by using these three.

[0021] like Figure 2 As shown, the battery-swap forklift 1 includes a non-standard split high-voltage battery system 13 and a body 11 of the battery-swap forklift 1, as shown in FIG. Figure 3-4 As shown, the non-standard split high-voltage battery system 13 includes: a battery pack 14, a battery-changing plug-in 15, a wiring harness 16, and a junction box 17. The junction box 17 is connected to the battery pack 14 through the battery-changing plug-in 15 and the wiring harness 16. The battery-changing plug-in 15 is a snap-on battery-changing plug-in 15, including a battery-changing plug 151 and a battery-changing socket 152. It is fixed by connecting the plug-in assistant buckle 153 on the battery-changing plug 151 with the card head on the battery-changing socket 152. The switching point socket is set on the battery pack 14, and the battery-changing plug 151 is connected to the wiring harness 16.

[0022] There is a battery compartment door 12 on the left side of the body 11 of the battery-swapping forklift 1. Make sure that the key switch of the battery-swapping vehicle is in the off state, that is, the entire vehicle is not powered; open the battery compartment door 12, and remove the battery-swapping plug-in 15 and the battery limit device in sequence; use a forklift to shovel out the battery side for battery-swapping operation.

[0023] Battery pack 14: battery module, internal wiring harness 16 and control assembly. The battery pack 14 is arranged in layers to improve space utilization. A slot is designed at the bottom of the battery pack 14 for forklift replacement of batteries. The internal wiring harness 16 is used for power transmission and battery cell voltage and temperature collection. The control assembly consists of a BMS control system, relays and control wiring harness 16, which can control the on and off of power and is also responsible for data monitoring and storage. The BMS in the control assembly has remote monitoring and data storage functions.

[0024] The battery swap plug-in 15 is provided with one DC high voltage, one grounding, one DC output port, communication, monitoring and low voltage interfaces. Among them, one DC high voltage: one interface each for total positive and total negative, with a rated current of not less than 250A and a withstand voltage of not less than 1000VDC; one DC output port: total positive and total negative, with a rated current of not less than 30A and a withstand voltage of not less than 1000VDC.

[0025] The battery swap plug-in 15 has a power-assisted design, which is more labor-saving and convenient to operate than direct plugging and unplugging. The material selection not only meets the plug-in and unplugging force requirements, but also the mechanical plug-in life must be no less than 5,000 times.

[0026] The junction box 17 provides an adapter interface for power output and communication for the entire machine, and is directly connected to the various actuators and communication lines of the forklift, reducing the number of plug-ins for the power exchange port.

[0027] like Figure 5 As shown, the explosion-proof box-type battery swap station 2 includes a container, a one-to-five charging pile 21, a thermal management system, a ventilation and exhaust system, an automatic fire extinguishing alarm system and a lighting system. The one-to-five charging pile 21, the thermal management system, the ventilation and exhaust system, the automatic fire extinguishing alarm system and the lighting system are arranged in the container, among which there are multiple one-to-five charging piles 21.

[0028] The explosion-proof box-type battery swap station 2 has the functions of battery swap, charging and delivery. Forklift users can choose to go to the explosion-proof box-type battery swap station 2 to swap batteries on their own or apply for delivery and battery swap on the battery swap scheduling cloud management platform 3. The battery swap scheduling cloud management platform 3 will dispatch the battery swap station to arrange battery delivery and battery swap. Its charging function can charge the replaced battery pack 14 through a one-to-five charging pile 21.

[0029] The one-to-five charging pile 21 modularizes the charging piles and installs the corresponding number of modular charging piles according to customer needs.

[0030] The container is explosion-proof and its size and layout can be designed according to customer needs. The explosion-proof materials and structural design can reduce the hazards caused by thermal runaway due to aging of lithium batteries or accidental short circuits.

[0031] The thermal management system includes an air-conditioning system and a water circulation system. The air-conditioning system of the battery swap station automatically adjusts according to the temperature of the battery. The water can be cooled and heated according to the temperature of the battery to enable the battery to be charged and stored at a suitable temperature, thereby increasing the battery life and reducing the cost of use.

[0032] The automatic fire extinguishing alarm system is used to monitor battery temperature and container detection. Through the coordinated work of sensors, control devices and fire extinguishing equipment, it is an intelligent fire-fighting facility that automatically detects, alarms and implements fire extinguishing when a fire occurs.

[0033] like Figure 6 As shown, the battery swap scheduling cloud management platform 3 includes: a charging and swapping WeChat applet and an online battery swap scheduling management cloud platform, and the online battery swap scheduling management cloud platform is accessed through the charging and swapping WeChat applet.

[0034] like Figure 6-7 As shown, a method of operating a high-voltage lithium-ion counterbalanced forklift battery replacement system: Forklift drivers can choose to go to a battery swap station to swap batteries on their own, or they can submit a battery swap application on the cloud management platform. After scheduling through the platform, the battery swap station will deliver and swap batteries. After the swap, the replaced batteries will be transported back to the battery swap station for charging. The online battery swap scheduling management cloud platform establishes sub-accounts to specifically manage the battery swap forklifts 1 and battery swap stations of different customers; the battery and vehicle data of the battery swap forklift 1 are uploaded to the online battery swap scheduling management cloud platform in real time, the real-time position of the battery swap forklift 1 and the battery is located, and the battery swap scheduling management is performed for the battery swap forklift 1; the battery is subjected to background data statistics and balanced management through the online battery swap scheduling management cloud platform, and the online battery swap scheduling management cloud platform solves the market problem that forklifts and batteries cannot be monitored synchronously.

[0035] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A high-voltage lithium-ion counterbalanced forklift battery replacement system, characterized in that: include: The battery-swap forklift is equipped with a split high-voltage battery system inside the body, which supplies power to the body of the battery-swap forklift; The explosion-proof box-type battery swap station has the functions of battery swapping, charging and delivery. Battery swap forklift users can choose to swap batteries at the station or apply for delivery and battery swapping on the cloud management platform. The battery swap dispatch cloud management platform provides special management for different customers' battery swap forklifts and explosion-proof box-type battery swap stations.

2. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 1, characterized in that: The split high-voltage battery system includes: a battery pack, a battery swap plug-in and wiring harness, and a junction box. The junction box is connected to the battery pack through the battery swap plug-in and wiring harness. The battery swap plug-in is a snap-on battery swap plug-in, including a battery swap plug and a battery swap socket. It is fixed by connecting the plug-in assistant buckle on the battery swap plug with the card head on the battery swap socket. The switching point socket is set on the battery pack, and the battery swap plug is connected to the wiring harness.

3. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 2, characterized in that the battery pack: The battery module, internal wiring harness and control assembly are arranged in layers inside the battery pack to improve space utilization. A slot is designed at the bottom of the battery pack for forklift replacement of batteries. The internal wiring harness is used for power transmission and battery cell voltage and temperature collection. The control assembly consists of a BMS control system, relays and control wiring harness, which can control the on and off of power and is also responsible for data monitoring and storage. The BMS in the control assembly has remote monitoring and data storage functions.

4. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 2, characterized in that: The battery swap plug-in is equipped with one DC high voltage port, one grounding port, one DC output port, communication, monitoring and low voltage interfaces.

5. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 4, characterized in that: One DC high voltage port: one total positive and one total negative port, with a rated current of not less than 250A and a withstand voltage of not less than 1000VDC; one DC output port: one total positive and one total negative port, with a rated current of not less than 30A and a withstand voltage of not less than 1000VDC.

6. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 1, characterized in that: The explosion-proof box-type battery swap station includes a container, a one-to-five charging pile, a thermal management system, a ventilation and exhaust system, an automatic fire-fighting alarm system and a lighting system. The one-to-five charging pile, the thermal management system, the ventilation and exhaust system, the automatic fire-fighting alarm system and the lighting system are arranged in the container, among which there are multiple one-to-five charging piles.

7. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 6, characterized in that: The thermal management system includes an air conditioning system and a water circulation system. The air conditioning system of the battery swap station is automatically adjusted according to the temperature of the battery. The water can be cooled and heated according to the temperature of the battery to enable the battery to be charged and stored at a suitable temperature.

8. The high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 6, characterized in that: The automatic fire extinguishing alarm system is used to monitor the temperature of batteries and containers. It is an intelligent fire-fighting facility that automatically detects, alarms and extinguishes fires when they occur through the coordinated work of sensors, control devices and fire-fighting equipment.

9. The high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 1, characterized in that: The battery swap scheduling cloud management platform includes: a charging and swapping WeChat applet and an online battery swap scheduling management cloud platform, and the online battery swap scheduling management cloud platform is accessed through the charging and swapping WeChat applet.

10. A high-voltage lithium-ion counterbalanced forklift battery replacement system according to claim 9, characterized in that: Its operation method: Forklift drivers can choose to go to a battery swap station to swap batteries on their own, or they can submit a battery swap application on the cloud management platform. After scheduling through the platform, the battery swap station will deliver and swap batteries. After the swap, the replaced batteries will be transported back to the battery swap station for charging. The online battery swap scheduling management cloud platform establishes sub-accounts to specifically manage the battery swap forklifts and battery swap stations of different customers; the battery and vehicle data of the battery swap forklift are uploaded to the online battery swap scheduling management cloud platform in real time to locate the real-time position of the battery swap forklift and battery, and perform battery swap scheduling management for the battery swap forklift; the online battery swap scheduling management cloud platform performs background data statistics and balancing management of the battery.

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