Full-automatic battery replacing method for battery replacing station
By using battery swapping robots to scan battery locations and automate battery replacement, the problem of existing battery swapping stations relying on manual operation has been solved, achieving an efficient and safe fully automated battery swapping process.
Patent Information
- Application Number
- CN202511825657.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-05
- Publication Date
- 2026-01-02
AI Technical Summary
Existing battery swapping stations rely heavily on manual intervention, resulting in low swapping efficiency, high risk of misoperation, and difficulty in achieving continuous large-scale operation.
A fully automated battery swapping method is adopted, which uses a battery swapping robot to scan the battery location, remove the old battery and replace it with a new one. The robot uses a 3D camera to obtain the battery location information, and the large and small robot bodies work together to locate, lift and replace the battery, thus realizing automated operation.
It has enabled fully automated battery replacement at battery swapping stations, improving swapping efficiency, reducing the risk of misoperation, and supporting continuous large-scale operations.
Smart Images
Figure CN121246734A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of battery swapping technology, specifically a fully automated battery swapping method for battery swapping stations. Background Technology
[0002] With the widespread adoption of pure electric heavy-duty trucks, short driving range, long charging time, and high initial purchase cost have become key issues restricting their development. To address these challenges, battery swapping has gradually emerged. Under this model, users can purchase vehicles without batteries and replenish their energy by leasing fully charged batteries from battery swapping stations. When the vehicle's battery is low, users simply drive into the swapping station to replace the battery pack, quickly restoring operation and effectively avoiding the excessively long charging times of traditional methods. In the electric truck sector, due to the large battery capacity required and long charging time, the industry generally adopts a design that fixes multiple battery packs onto a mounting frame to form an integrated battery pack, along with dedicated battery swapping stations. Battery swapping stations typically include a charging box and a battery transport device. The charging box contains monitoring equipment, a control cabinet, a charger, and battery packs to be charged, while the battery transport device is responsible for transferring the battery packs between the vehicle and the charging box.
[0003] However, existing battery swapping stations still heavily rely on manual intervention in actual operation. For example, the positioning, disassembly, hoisting, and charging management of battery packs all require operator involvement, resulting in low swapping efficiency, high risk of misoperation, and difficulty in achieving continuous, large-scale operations. This low level of automation has become a bottleneck restricting the widespread adoption of battery swapping. Therefore, a fully automated battery swapping method for battery swapping stations is urgently needed. Summary of the Invention
[0004] In view of this, the present invention addresses the shortcomings of the prior art by providing a fully automated battery swapping method for battery swapping stations.
[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a fully automated battery swapping method for battery swapping stations, comprising the following steps: S1. Scan the location of the trucks waiting to be swapped at the battery swapping station to obtain the location information of the truck batteries; S2. The battery swapping robot removes the battery from the truck to be swapped based on the truck's battery location information and replaces it with a new battery. S3. The battery swapping robot performs a battery swapping operation on the removed batteries.
[0006] Furthermore, in S1, after the truck to be swapped stops in the designated scanning area and waits for the vehicle unlocking signal, the host system issues a swapping command. Upon receiving the command, the swapping robot first moves to its initial position and then notifies the 3D camera to scan the truck. If the scan fails to obtain the truck's battery location information, the swapping robot's PLC sends a scan failure code and waits for a new swapping command signal. If the scan is successful and the 3D camera provides the battery coordinate signal, the swapping robot's PLC sends a normal result signal and simultaneously starts the swapping task process.
[0007] Further, in S2, the main body of the battery swapping robot automatically moves above the actual parking space. Then, the lifting mechanism begins to descend to the target battery position fed back by the 3D camera. The gripper then closes. After closure, the lifting mechanism lifts the lifting device into the guide tube. The smaller robot body first moves to the middle aisle position, and the main robot body then automatically moves to the aisle where the target empty battery compartment is located. After the smaller robot body moves above the target empty compartment, it lifts and lowers to the correct position, opens the gripper, and releases the battery. After lifting again, the main robot body and the smaller robot body move in tandem to the target full battery compartment, lower to the correct position, close the gripper, lift again, and the smaller robot body moves to the corresponding aisle position. The main robot body then continues to move to the initial point of the aisle. The main robot body and the smaller robot body move in tandem to above the actual position of the truck, lift and lower to the correct position, open the gripper, and release the battery. After lifting again, it automatically returns to the initial parking position, and the battery swapping task ends.
[0008] Furthermore, in S3, the host system sends a battery swapping command along with the corresponding battery retrieval and placement bays. Upon receiving the command, the battery swapping robot automatically moves to the battery retrieval bay, lifts and lowers, closes the gripper, grabs the battery, lifts it into the guide tube, then moves the robot's trolley to the middle channel position, and then moves the robot's main body to the channel position corresponding to the target battery placement bay. The robot's trolley then moves to the target battery placement bay, lifts and lowers, opens the gripper after reaching the position, lifts it into the guide tube, and then automatically returns to the initial position, completing the battery swapping process.
[0009] Furthermore, the battery swapping robot includes a large robot body that moves along the top track of the battery swapping station, a small robot body mounted on the large robot body and perpendicular to the direction of movement of the large robot body, a lifting and hoisting mechanism mounted on the small robot body, a lifting device connected to the lower part of the lifting and hoisting mechanism, and a clamp rotatably mounted on the lower part of the lifting device.
[0010] Furthermore, the robot's main body includes a rectangular frame and first traveling wheels set at the four corners of the rectangular frame. The four first traveling wheels are set in pairs on the two side tracks, and the two first traveling wheels on the same side on different tracks are driven by the first motor.
[0011] Furthermore, the robot body includes an I-shaped frame and second wheels set at the four corners of the I-shaped frame. Guide rails are set on both sides of the rectangular frame perpendicular to the track. The four second wheels are set on the two side guide rails in pairs. The two second wheels on the same side located on different guide rails are driven by the second motors respectively.
[0012] Furthermore, the lifting hoisting mechanism includes two double-drum hoists positioned opposite each other in the middle of the I-shaped frame.
[0013] Furthermore, the lifting device includes a top frame, fixed pulleys at the four corners of the top surface of the top frame, and a gear rotary table at the center of the bottom surface of the top frame. The four slings of the two double-drum winches are respectively hung on the four fixed pulleys, and the gear rotary table is driven by a third motor located on the top surface of the top frame.
[0014] Furthermore, the fixture includes a base frame, guide blocks fixedly mounted on both sides of the bottom surface of the base frame, and two L-shaped grippers positioned opposite each other between the two guide blocks. The center of the top surface of the base frame is connected to the bottom of the gear rotary table. The two ends of the two L-shaped grippers are connected by a bidirectional lead screw, which is driven by a fourth motor.
[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention relates to a fully automated battery swapping method for battery swapping stations. When a truck to be swapped arrives at the designated scanning area of the battery swapping station, a 3D camera scans the truck's location to obtain the location information of the truck's batteries. Then, a battery swapping robot removes the batteries from the truck to be swapped and replaces them with new batteries, thus achieving automated battery swapping. In addition, the robot performs a compartment swapping operation on the swapped batteries to enable unified management based on battery power.
[0016] This invention relates to a fully automated battery swapping method for battery swapping stations. The battery swapping robot consists of a large robot body that moves along a track at the top of the station, a smaller robot body mounted on the large robot body and perpendicular to its direction of movement, a lifting and hoisting mechanism mounted on the smaller robot body, a lifting device connected to the lower part of the lifting and hoisting mechanism, and a clamp rotatably mounted below the lifting device. This enables the robot to move along the X, Y, and Z axes (lifting) and the N axis (rotation). On the one hand, it satisfies the requirement of automated lifting, replacement, and placement of batteries, achieving fully automated battery swapping. On the other hand, the clamp and the lifting device are rotatably connected. When the truck to be swapped has a deflection angle, the battery swapping robot controls the clamp to rotate a certain angle based on the truck battery position information from a 3D camera to achieve battery positioning, lifting, and replacement, providing high flexibility. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the battery swapping robot in an embodiment of the present invention; Figure 2 This is a structural schematic diagram of the lifting device from one perspective in an embodiment of the present invention; Figure 3 This is a structural schematic diagram of the lifting device from another perspective in an embodiment of the present invention; Figure 4 This is a structural schematic diagram of the clamp from one perspective in an embodiment of the present invention; Figure 5 This is a structural schematic diagram of the clamp from another perspective in an embodiment of the present invention.
[0018] In the diagram: 1-track, 2-lifting device, 3-clamp, 4-control box, 5-rectangular frame, 6-first traveling wheel, 7-first motor, 8-I-shaped frame, 9-second traveling wheel, 10-guide rail, 11-second motor, 12-double drum winch, 13-sling, 14-guide cylinder, 15-battery, 21-top frame, 22-fixed pulley, 23-gear rotary table, 24-third motor, 25-reducer, 26-drive gear, 31-base frame, 32-guide block, 33-L-shaped gripper. Detailed Implementation
[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention are within the scope of protection of the present invention.
[0020] Example 1: A fully automated battery swapping method for battery swapping stations, the steps of which are as follows: Step 1: Scan the location of the trucks arriving at the battery swapping station to obtain the location information of the truck batteries, as follows: After the battery swapping truck stops in the designated scanning area and waits for the vehicle unlock signal, the host system issues a battery swapping command. Upon receiving the command, the battery swapping robot first moves to its initial position and then notifies the 3D camera to scan the truck. If the scan fails to obtain the truck's battery location information, the battery swapping robot's PLC sends a scan failure code and waits for a new battery swapping command signal. If the scan is successful and the 3D camera provides the battery coordinate signal, the battery swapping robot's PLC sends a normal result signal and simultaneously starts the battery swapping task process.
[0021] Step 2: Based on the truck's battery location information, the battery swapping robot removes the battery from the truck to be swapped and replaces it with a new one, as detailed below: The battery swapping robot's main body automatically moves above the actual parking space. Then, the lifting mechanism descends to the target battery location fed back by the 3D camera, and the gripper closes. After closure, the lifting mechanism raises the lifting device into the guide tube. Next, the smaller robot body moves to the middle aisle, and the main robot body automatically moves to the aisle containing the target empty battery compartment. The smaller robot body then moves above the target empty compartment, lowers and lifts to its designated position, opens the gripper, and releases the battery. After lifting again, the main and smaller robot bodies move in tandem to the target full battery compartment, lower to its designated position, close the gripper, and lift again. The smaller robot body moves to its corresponding aisle position, and the main robot body continues to move to the initial point of the aisle. The main and smaller robot bodies then move in tandem to the actual location of the truck, lower and lift, open the gripper, and release the battery. After lifting again, the robot body automatically returns to the initial parking position, completing the battery swapping task.
[0022] Step 3: The battery swapping robot performs a compartment swapping operation on the removed batteries, as detailed below: The host system sends a battery swapping command along with the corresponding battery retrieval and placement positions. Upon receiving the command, the battery swapping robot automatically moves to the battery retrieval position, lifts and lowers, closes its gripper, grabs the battery, lifts it into the guide tube, then moves its trolley to the middle channel position, and then moves its main body to the channel position corresponding to the target battery placement position. The trolley then moves to the target battery placement position, lifts and lowers, opens its gripper upon arrival, lifts it into the guide tube, and then automatically returns to its initial position, completing the battery swapping process.
[0023] Reference Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5The battery swapping robot used in the fully automated battery swapping method for battery swapping stations in this embodiment of the invention consists of six parts: a large robot body that moves along the top track 1 of the battery swapping station; a small robot body that is mounted on the large robot body and perpendicular to the direction of movement of the large robot body; a lifting and hoisting mechanism mounted on the small robot body; a lifting device 2 connected to the lower part of the lifting and hoisting mechanism; a clamp 3 that is rotatably mounted on the lower part of the lifting device 2; and a control box 4 located on one side of the large robot body.
[0024] The robot's main body includes a rectangular frame 5 and first traveling wheels 6 set at the four corners of the rectangular frame 5. The four first traveling wheels 6 are set in pairs on the two side tracks 1. The two first traveling wheels 6 on the same side on different tracks 1 are driven by the first motor 7 respectively.
[0025] The robot body includes an I-shaped frame 8 and second wheels 9 set at the four corners of the I-shaped frame 8. Guide rails 10 are set on both sides of the rectangular frame 5 perpendicular to the track 1. The four second wheels 9 are set on the two guide rails 10 in pairs. The two second wheels 9 on the same side located on different guide rails 10 are driven by the second motor 11 respectively.
[0026] The hoisting mechanism includes two double-drum winches 12 that are positioned opposite each other in the middle of the I-shaped frame 8.
[0027] The lifting device 2 includes a top frame 21, fixed pulleys 22 at the four corners of the top surface of the top frame 21, and a gear rotary table 23 at the center of the bottom surface of the top frame 21. The four slings 13 of the two double-drum winches 12 are respectively hung on the four fixed pulleys 22. The gear rotary table 23 is driven by a third motor 24 located on the top surface of the top frame 21. The third motor 24 is connected to a reducer 25. A drive gear 26 is installed on the output shaft of the reducer 25, and the drive gear 26 meshes with the gear rotary table 23 for transmission. Conical guide columns are provided on both sides of the top surface of the top frame 21, and guide cylinders 14 are provided on both sides of the bottom surface of the rectangular frame 5 of the robot's main body. When the lifting device 2 rises to the bottom of the robot's main body, the conical guide columns enter the guide cylinders 14 to prevent the lifting device 2 and the battery 15 from swaying during movement.
[0028] The clamp 3 includes a base frame 31, guide blocks 32 fixedly mounted on both sides of the bottom surface of the base frame 31, and two L-shaped grippers 33 positioned opposite each other between the two guide blocks 32. The center of the top surface of the base frame 31 is connected to the bottom of the gear rotary disk 23. The two ends of the two L-shaped grippers 33 are connected by a two-way lead screw, which is driven by a fourth motor. There are six guide blocks on both sides of the guide blocks 32, which are inclined on the outside and inserted into the positioning holes of the upper frame of the battery 15. The two L-shaped grippers 33 move back to back and are respectively moved to the bottom of the cross brace of a battery frame for clamping and fixing.
[0029] The control box 4 houses a PLC. The 3D camera, the large robot body, the small robot body, the lifting and hoisting mechanism, the lifting device 2, and the clamp 3 are all connected to the PLC via signals. The 3D camera acquires the battery coordinate signals and sends them to the PLC. The PLC controls the actions of the large robot body, the small robot body, the lifting and hoisting mechanism, the lifting device 2, and the clamp 3, performing steps two and three as described above. Furthermore, when scanning the truck battery location, the 3D camera can capture the battery's angle and transmit it to the PLC. The PLC then controls the gear rotary table 23 of the lifting device 2 to rotate, causing the clamp 3 to rotate by the same angle. The lifting device 2 then descends and locks the battery frame for lifting.
[0030] The above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art can still make modifications or equivalent substitutions to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention are within the protection scope of the claims of the present invention.
Claims
1. A full-automatic battery swapping method for a battery swapping station, characterized in that, The method comprises the following steps: S1, scanning the position of the truck to be replaced with battery at the battery replacement station to obtain the battery position information of the truck; S2, the battery replacement robot removes the battery on the truck to be replaced with battery according to the battery position information of the truck, and replaces a new battery; S3, the battery replacement robot performs the battery replacement operation on the removed battery. 2.The full-automatic battery swapping method for a battery swapping station according to claim 1, wherein: In S1, after the truck to be replaced with battery stops in the designated scanning area, the vehicle is unlocked and the signal is sent to the position, the upper system gives the battery replacement command, the battery replacement robot receives the command, the battery replacement robot first runs to the initial position, then notifies the 3D camera to scan the truck, if the battery position information of the truck is obtained after scanning, the PLC of the battery replacement robot feeds back the scanning failure code, and waits for a new battery replacement instruction signal; after the 3D camera gives the battery coordinate signal, the PLC of the battery replacement robot feeds back the normal signal, and the task flow of starting the battery replacement is started. 3.The full-automatic battery swapping method for a battery swapping station according to claim 1, wherein: In S2, the robot car body automatically runs to the actual parking position, then the lifting mechanism starts to descend to the target battery position fed back by the 3D camera, then the clamp starts to close, after the closing is completed, the lifting mechanism starts to lift the lifting tool into the guide cylinder; then the robot car body first runs to the middle channel position, the robot car body automatically runs to the channel where the target empty battery compartment is located, then the robot car body runs to the target empty battery compartment, the lifting mechanism descends to the position, the clamp is opened, and the battery is released; after the lifting mechanism is lifted again, the robot car body and the robot car body are linked to run to the target full battery compartment, the lifting mechanism is lowered to the position, the clamp is closed, the lifting mechanism is lifted again, the robot car body runs to the corresponding channel position, the robot car body continues to run to the channel initial point, the robot car body and the robot car body are linked to run to the actual position of the truck, the lifting mechanism is lowered, the clamp is opened after being lowered to the position, and the battery is released; after the lifting mechanism is lifted, it automatically returns to the initial parking position, and the battery replacement task is completed. 4.The full-automatic battery swapping method for a battery swapping station of claim 1, wherein: In S3, the upper system sends the battery replacement command and the corresponding battery replacement battery taking compartment and battery replacement battery placing compartment; after receiving the command, the battery replacement robot automatically runs to the position above the battery replacement battery taking compartment, the lifting mechanism is lowered, the clamp is closed, the battery is grabbed after the lifting mechanism is lifted into the guide cylinder, then the robot car body moves to the middle channel position, the robot car body moves to the channel position corresponding to the target battery replacement battery placing compartment, then the robot car body moves to the position above the target battery replacement battery placing compartment, the lifting mechanism is lowered, the clamp is opened after being lowered to the position, and the process is completed; after the lifting mechanism is lifted into the guide cylinder, it automatically returns to the initial position, and the battery replacement process is completed. 5.The full-automatic battery swapping method for a battery swapping station according to any one of claims 1-4, characterized in that: The battery replacement robot comprises a robot car body moving along the top rail of the battery replacement station, a robot car body vertically arranged on the robot car body and moving in the direction of the robot car body, a lifting winch mechanism arranged on the robot car body, a lifting tool connected to the lower part of the lifting winch mechanism, and a clamp rotatably arranged on the lower part of the lifting tool. 6.The full-automatic battery swapping method for a battery swapping station according to claim 5, wherein: The robot car body comprises a rectangular frame and four first walking wheels arranged at the four corners of the rectangular frame, two first walking wheels on the same side of different rails are driven by a first motor respectively. 7.The full-automatic battery swapping method for a battery swapping station according to claim 6, characterized in that: The robot trolley body comprises an I-shaped frame and second walking wheels arranged at four corners of the I-shaped frame, two sides of the rectangular frame perpendicular to the track are provided with guide rails, and two second walking wheels are arranged on each of the two sides of the guide rails. 8.The full-automatic battery swapping method for a battery swapping station according to claim 7, characterized in that: The lifting winch mechanism comprises two double-drum winches arranged oppositely in the middle of the I-shaped frame. 9.The full-automatic battery swapping method for a battery swapping station according to claim 8, characterized in that: The lifting tool comprises a top frame, four fixed pulleys arranged at four corners of the top surface of the top frame, and a gear rotating disc arranged at the center of the bottom surface of the top frame, four lifting ropes of the two double-drum winches are hung on the four fixed pulleys respectively, and the gear rotating disc is driven by a third motor arranged on the top surface of the top frame. 10.The full-automatic battery swapping method for a battery swapping station according to claim 9, wherein: The clamp comprises a bottom frame, two guide blocks fixedly arranged on both sides of the bottom surface of the bottom frame, and two L-shaped clamping jaws arranged oppositely between the two guide blocks, the center of the top surface of the bottom frame is connected with the bottom of the gear rotating disc, the two ends of the two L-shaped clamping jaws are connected through a double-threaded screw respectively, and the two double-threaded screws are driven by a fourth motor.