Monitoring and anti-falling system and method for battery replacement process of battery replacement equipment

Abstract

The invention discloses a monitoring and anti-falling system and method for a battery replacing process of battery replacing equipment, and belongs to the technical field of electric automobile battery replacing equipment. The system comprises a monitoring unit, an anti-falling unit and a vibration reduction unit. The monitoring unit is composed of a pressure sensor, a contact type vibration sensor, a non-contact type vibration sensor, a deformation sensor, an environment temperature sensor, a speed sensor, a collision sensor and a visual camera and used for monitoring stress, vibration, displacement, temperature and environment states in the battery replacement process in real time. The anti-falling unit is provided with an anti-falling fork arm, a pop-up device and a hydraulic supporting mechanism, and when it is detected that the battery is grabbed abnormally or tends to fall, the fork arm is actively popped up and matched with hydraulic supporting to prevent falling or relieve impact. The vibration reduction unit is composed of a positioning column and a fixed bearing, and when it is detected that the vibration amplitude or deflection angle of the battery exceeds the limit, the vibration reduction unit is automatically meshed with a limiting hole to restrain shaking. According to the system, multi-dimensional monitoring and active protection in the battery replacement process are achieved, and the risk of battery falling can be effectively avoided.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of electric vehicle battery swap equipment, and particularly relates to a battery swap equipment battery swap process monitoring and falling prevention system and method. BACKGROUND

[0002] Currently, with the rapid development of the new energy vehicle industry, the energy supply mode of electric vehicles is gradually changing from the traditional charging mode to the efficient battery swap mode. The battery swap station, as an important infrastructure for energy supply of battery swap vehicles, mainly functions to realize automatic replacement of power batteries to improve the energy supply speed and operation efficiency of vehicles. The battery swap system is usually composed of a battery swap robot, a charging module, a storage battery compartment, a control system and the like, wherein the battery swap robot is responsible for grabbing, carrying and installing the battery, and is the core link of the entire system operation. However, during the battery replacement process, the battery needs to go through actions such as grabbing, lifting, translation and descending, and the working environment is mostly located outdoors, which is affected by factors such as wind sand, rain and temperature changes, and is prone to dangerous conditions such as battery shaking, deviation and even falling. Especially for heavy-load batteries with large tonnage, the stability and safety problems in the battery swap process are more prominent.

[0003] In the prior art, the monitoring of the running state of the battery swap station mainly focuses on the vehicle parking position, the charging machine working state and the overall operation and maintenance of the battery swap station, and typical schemes such as patent CN120270088A only realize the collection and state evaluation of the running data of the battery swap station. The safety monitoring system of the lifting vehicle type battery swap station disclosed in patent CN118953280A introduces safety detection modules such as gratings and pressure sensitive devices, but mainly for the safety protection of the vehicle and the platform, and lacks targeted monitoring and intervention functions for the actual battery swap process of the battery swap robot. Another representative scheme, such as patent 202411995789.9, sets a mechanical brake on the battery transfer device to trigger the brake when the lifting speed exceeds the preset range, thereby preventing the equipment from falling. However, this kind of technical scheme has significant limitations: the anti-falling mechanism relies on the speed change signal, and when the grabbing mechanism causes the battery to fall statically due to mechanical fatigue, structure fracture or failure, the speed sensor cannot capture the abnormality, so that the anti-falling device cannot respond in time and cannot effectively prevent the battery from falling.

[0004] In addition, the existing anti-falling system is mainly mechanical safety rope or brake, which has limited installation space, poor compatibility, and can only adapt to specific models of battery replacement robots, making it difficult to be popularized in different specifications of battery replacement stations. At the same time, the traditional monitoring system relies on single sensor or electrical control signal, which has single data source and insufficient redundancy. When the sensing element is damaged or communication is abnormal, the system is prone to misjudgment or failure risk, and cannot realize multi-dimensional and multi-level safety state recognition. The battery replacement robot may also be affected by micro-vibration and structural deformation during battery carrying. Although these factors cannot immediately cause falling, they can accelerate mechanical fatigue, reduce equipment life, and cause battery replacement accuracy to decrease.

[0005] Therefore, the prior art still lacks a system that can comprehensively monitor the stress, vibration, displacement and environmental state of the battery during the entire battery replacement process, and actively take anti-falling and vibration reduction measures when detecting abnormal trends. In view of the multi-source risks such as fracture of the grabbing mechanism of the battery replacement robot, deformation of the mechanical arm, and shaking and deflection of the battery, a compact, responsive and independent battery replacement process monitoring and anti-falling system is needed to realize the technical upgrade from "passive protection" to "active early warning and intervention", so as to improve the safety and reliability of the battery replacement equipment. SUMMARY

[0006] The purpose of the present application is to solve the problem in the prior art that the battery replacement equipment lacks targeted monitoring and effective anti-falling measures during the battery replacement process, resulting in the battery being prone to falling due to vibration, deflection or fracture of the grabbing mechanism, and the safety and success rate of battery replacement being insufficient.

[0007] The purpose of the present application is achieved by the following technical solutions: A battery replacement equipment battery replacement process monitoring and anti-falling system, comprising a monitoring unit, an anti-falling unit and a vibration reduction unit; Among them, The monitoring unit is arranged on the grabbing mechanism and the frame of the battery replacement robot, and comprises a pressure sensor, a contact vibration sensor, a non-contact vibration sensor, a deformation amount sensor, an environmental temperature sensor, a battery moving speed sensor, a collision sensor and a vision camera; The anti-falling unit comprises a hook anti-falling device arranged on the upper part of the battery replacement robot and a fork-shaped follow-up anti-falling device fixed to the lower part of the battery replacement robot; The vibration reduction unit comprises a telescopic positioning column and a fixed bearing. When the monitoring unit detects that the vibration amplitude or the deflection angle of the battery exceeds the set threshold, the positioning column automatically extends and engages with the deep groove ball bearing in the limiting hole on the battery outer frame, so as to suppress shaking and stabilize the battery posture; The monitoring unit is used to calculate the overall force distribution of the battery, and triggers the action of the anti-falling unit when any sensor signal disappears or the change speed exceeds the preset threshold. Preferably, the fork-shaped follow-up anti-falling device comprises anti-falling fork arms, a pop-up device, and a hydraulic support mechanism. The pop-up device is connected to the battery changing robot frame through a guide rail and can move up and down. When the monitoring unit detects abnormal force or falling trend of the battery, the pop-up device drives the anti-falling fork arms to extend to the lower side of the battery, and the hydraulic support mechanism generates a reverse support force to prevent or alleviate the falling of the battery.

[0008] Preferably, the non-contact vibration sensor adopts a laser ranging method, which calculates the vibration spectrum and deflection angle by detecting the vibration displacement of the battery surface marker.

[0009] Preferably, the anti-falling fork arms are composed of multiple support rods and are simultaneously driven by the pop-up device to form a multi-point support structure. The support points are linked with the hydraulic support mechanism to disperse the impact load.

[0010] Preferably, the hydraulic support mechanism maintains a pressure release state in the non-working state, and quickly establishes a working pressure after detecting the falling signal to achieve instantaneous lifting and buffering.

[0011] Preferably, the positioning column of the vibration reduction unit is telescopic through an electric control driving module. After extension, it forms a rotating fit with a deep groove ball bearing, thereby allowing the battery to be slightly self-adjusted while being limited to prevent structural interference.

[0012] Preferably, the visual camera is arranged on the shell of the battery changing station, used to identify the battery changing process stage and position state, and fuse the visual information with the sensor data for abnormality judgment.

[0013] Based on the same inventive concept, the application also provides a battery changing equipment battery changing process monitoring anti-falling method, applied to the system as described above, characterized in that it comprises the following steps: S10: During the battery grabbing, lifting, translation, and descending process, real-time collection of battery state data is performed by using pressure, vibration, deformation, temperature, and speed sensors; S20: Comparison and analysis of the collected data are performed to determine whether there is force imbalance, structural deformation, or vibration deviation; S30: When the battery grabbing abnormality or falling trend is detected, the pop-up device of the anti-falling unit is controlled to drive the anti-falling fork arms to extend to the lower side of the battery, and the hydraulic support mechanism is simultaneously started to provide lifting support force; S40: When the vibration amplitude or deflection angle exceeds the limit, the positioning column of the vibration reduction unit is controlled to extend and engage with the fixed bearing to realize the stability of the battery posture. S50: During the whole battery replacement process, the system continuously monitors and dynamically adjusts the anti-falling and vibration reduction response according to real-time data.

[0014] Preferably, before triggering the anti-falling unit in step S30, a multi-sensor consistency check is performed on the monitoring signal to exclude single-point false alarms.

[0015] Preferably, in step S40, the threshold of the deflection angle is set to 4°, and when the threshold is exceeded, the vibration reduction unit is automatically triggered to extend the positioning column to maintain the stability of the battery replacement.

[0016] Compared with the prior art, the present application has the following advantages: The present application forms a complete "perception-judgment-execution" safety protection system by integrating multi-dimensional monitoring units, anti-falling units and vibration reduction units in the structure of the battery replacement robot, realizing closed-loop control from state monitoring to active protection. The core technical feature is the cooperative response principle of multi-source sensing monitoring and mechanical protection mechanism. The monitoring unit is cooperatively laid out by multiple points of pressure sensors, contact and non-contact vibration sensors, deformation sensors, environmental temperature sensors, battery moving speed sensors, collision sensors and visual cameras, which can obtain real-time information of battery stress state, structural deformation, vibration spectrum, displacement speed and environmental changes during the whole process of battery grabbing, lifting, translation and descending. After the data collected by the sensors are compared and identified by the system, it can quickly judge whether there is a mechanical abnormality, stress imbalance or vibration deviation risk. When the monitoring result exceeds the set threshold, the system triggers the anti-falling or vibration reduction mechanism through control logic in time, so that the safety protection of the battery replacement process is changed from passive response after the event to early warning and active intervention.

[0017] The design of the anti-falling unit of the present application embodies a unique mechanical response principle. The unit is composed of anti-falling fork arms, a pop-up device and a hydraulic support mechanism, wherein the pop-up device is connected with the frame of the battery replacement robot through guide rails and can move up and down synchronously with the height of the battery. When the monitoring system judges that the battery has a downward trend or the grabbing mechanism is abnormal, the electric control system immediately drives the pop-up device, and the fork arms quickly extend to form a supporting structure under the battery. At the same time, the hydraulic support mechanism establishes a reverse supporting force in a short time, so that the fork arms generate a strong upward force to offset the gravity impact of the battery falling. Its working mechanism is equivalent to that when the system detects a potential falling, through the instantaneous release of mechanical force and the conversion of hydraulic energy, a dynamic anti-falling process of "active support - deceleration buffer - energy absorption" is realized, so as to effectively prevent the battery from falling or significantly reduce the impact energy. Compared with the traditional anti-falling technology relying on the speed of the brake, the present application triggers the mechanical support through multi-dimensional state monitoring, breaking through the limitation of relying on displacement speed change, and still plays a protective role in the extreme case of mechanical fracture or static falling.

[0018] The mechanism of the vibration reduction unit of the application embodies the principle of structure stability control. The unit is composed of an extendable positioning column and a fixed bearing. When the vibration amplitude of the battery exceeds the set threshold or the deflection angle exceeds 4°, the system automatically drives the positioning column to extend and engage with the deep groove ball bearing in the limiting hole on the battery outer frame, forming a high-precision lateral limiting support. By mechanical engagement, the lateral shaking and micro-vibration during battery replacement are eliminated, which not only improves the battery positioning accuracy and the stability of the robot grabbing, but also significantly reduces the structural fatigue caused by repeated vibration. The physical principle of this active limiting method is to disperse the dynamic load to multiple support points by changing the force transmission path, thereby reducing the single-point stress concentration and achieving structure vibration reduction and stable control.

[0019] In summary, the application realizes a multi-layer closed-loop system of "multi-source information fusion monitoring - active mechanical intervention protection - structure dynamic stability control" in principle, and the technical effect is remarkable. Firstly, real-time monitoring and abnormal early warning can be realized during the whole battery replacement process, which greatly improves the safety and reliability of the system. Secondly, through the linkage of mechanical and hydraulic anti-falling structures, timely intervention can be made in the event of fracture, slipping, impact and other failure conditions to prevent battery falling from causing equipment damage or personal injury. Thirdly, through the limiting support mechanism of the vibration reduction unit, the battery shaking and deflection are effectively reduced, and the replacement accuracy and efficiency are improved. Fourthly, the overall structure of the system is modularized and has strong independence, which can be applied to the existing battery replacement station at low cost, taking into account the universality and maintenance convenience. Therefore, the application not only fundamentally solves the problem of disconnection between monitoring and protection during battery replacement, but also provides a popular and systematic solution for the safety and intelligence of electric vehicle battery replacement technology. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 FIG. 1 is a three-dimensional structural schematic diagram of a battery replacement equipment battery replacement process monitoring and anti-falling system according to the application; Figure 2 FIG. 3 is a schematic diagram of the installation position of the sensor on the grabbing mechanism in the application; Figure 3 FIG. 4 is a schematic diagram of the installation position of the sensor on the battery replacement robot frame in the application; Figure 4 FIG. 5 is a three-dimensional structural schematic diagram of the hook anti-falling device in the application; Figure 5 FIG. 6 is a structural schematic diagram of the retracted state of the hook anti-falling device in the application; Figure 6 FIG. 7 is a structural schematic diagram of the extended state of the hook anti-falling device in the application; Figure 7 FIG. 8 is a three-dimensional structural schematic diagram of the fork-shaped follow-up anti-falling device in the application; Figure 8This is a three-dimensional structural schematic diagram of the vibration reduction unit in this invention; The components include: 1. Monitoring unit, 2. Anti-fall unit, 3. Vibration reduction unit, 11. Pressure sensor, 12. Contact vibration sensor, 13. Non-contact vibration sensor, 14. Deformation sensor, 15. Ambient temperature sensor, 16. Collision sensor, 17. Battery movement speed sensor, 21. Hook anti-fall device, 22. Fork-shaped follow-up anti-fall device, 31. Drive unit, 32. Fixed bearing, 33. Telescopic positioning column, 100. Battery swapping robot, 101. Grasping mechanism, 102. Frame, 200. Battery outer frame, 211. Drive component, 212. Locking pin guide support seat, 213. Locking pin, 221. Telescopic fork assembly, 222. Follow-up mechanism, 2211. Anti-fall fork arm, 2212. Telescopic drive device, 2221. Lifting drive, 2222. Helical screw assembly. Detailed Implementation

[0021] The technical solution will be further described below with reference to the accompanying drawings and specific embodiments to help understand the content of the present invention.

[0022] Example 1 like Figures 1-3 As shown, a monitoring and anti-fall system for battery swapping equipment includes: a monitoring unit 1, an anti-fall unit 2, and a vibration reduction unit 3.

[0023] The monitoring unit 1 is mounted on the gripping mechanism 101 and its frame 102 of the battery swapping robot 100, and includes a pressure sensor 11, a contact vibration sensor 12, a non-contact vibration sensor 13, a deformation sensor 14, an ambient temperature sensor 15, a collision sensor 16, a battery movement speed sensor 17, and a vision camera. The anti-fall unit 2 includes a hook anti-fall device 21 mounted on the upper part of the battery swapping robot 100 and a fork-shaped follow-up anti-fall device 22 fixed to the lower part of the battery swapping robot 100. To ensure the real-time performance and reliability of the monitoring data, each sensor in the monitoring unit is communicatively connected to the main control board of the battery swapping robot control system, using an RS485 bus or CAN bus for data acquisition and command feedback. The system sampling frequency is preferably 10–50 Hz to ensure that dynamic changes during battery gripping and lifting can be accurately captured. All sensor signals are filtered and calibrated before being input into the data fusion module, where moving average and Kalman filtering algorithms are used to smooth the signals to eliminate errors caused by mechanical vibration and environmental interference.

[0024] like Figure 2As shown, the pressure sensor 11, the contact vibration sensor 12, the non-contact vibration sensor 13, the deformation sensor 14, and the environmental temperature sensor 15 are arranged on the grabbing mechanism 101; the deformation sensor 14 is six in total and is arranged on the two sides of the frame of the grabbing mechanism 101 in six positions in total, three on each side. The pressure sensor 11 is installed on the battery load bearing part of the battery swapping robot grabbing mechanism, and multiple pressure sensors are arranged when multi-surface bearing is required, which is used to calculate the lifting force of the whole battery; the contact vibration sensor 12 is also installed on the part of the battery swapping robot grabbing mechanism that contacts the battery, which is used to measure the vibration of the battery during the replacement process; the non-contact vibration sensor 13 is installed in the middle of the frame of the battery swapping robot, and a mark point is attached to the battery, and the vibration of the mark point is measured by laser; the deformation sensor 14 is in the form of a strain gauge and is installed on multiple points of the force-bearing frame of the battery swapping robot, which is used to monitor the elastic deformation of multiple points of the battery swapping robot during bearing movement; the environmental temperature sensor 15 is installed in the middle of the frame of the battery swapping robot, which measures the overall environmental temperature; the battery moving speed sensor is installed on the robot and measures the up-and-down moving speed of the battery in a non-contact manner.

[0025] The grabbing mechanism 101 of the battery swapping robot is installed with the environmental temperature sensor 15 and other sensors on the upper plane, which can closely sense the temperature of the battery; the grabbing hooks of the grabbing mechanism are the force-bearing surfaces that contact the outer frame 200 of the battery and are installed with four pressure sensors 11 that are distributed on the four hooks and can bear the whole weight of the battery; the grabbing mechanism is also installed with the contact vibration sensor 12 that can measure the vibration of the battery. The deformation sensor is installed on the frame surface of the grabbing mechanism and can measure the deformation of the battery during bearing, which can provide a warning for damage.

[0026] The state of the battery swapping robot when grabbing the battery is as shown in Figure 3 The collision sensor is arranged on the frame of the battery swapping robot, which can provide a warning for the collision between the battery and the battery swapping robot during the transfer of the battery; the speed sensor is also arranged on the frame, which can measure the speed of the battery movement. The collision sensor 16 is arranged in the middle of the column of the frame 102 on one side of the battery swapping robot; the battery moving speed sensor 17 is arranged in the middle of the crossbeam on the top of the frame 102 of the battery swapping robot. The collision sensor 16 is installed on the frame of the battery swapping robot and monitors whether the battery is subjected to collision in a visual manner; the visual camera is installed on the shell of the battery swapping station and can recognize the whole view of the battery swapping, which is used to determine which process the battery swapping is in.

[0027] As shown in Figure 4 The hook anti-falling device 21 is mainly used to prevent the hook from breaking and the battery from falling; the device includes a driving member 211, a locking pin 213, and a locking pin guiding support seat 212; when the pressure sensor detects abnormal pressure change, the locking pin 213 is automatically extended, which can avoid the battery from falling due to the breaking of the hook.Figure 5 is the state of the locking pin retraction, Figure 6 is the state of the locking pin extension. The material of the locking pin 213 is preferably high-strength alloy steel, and the surface is carburized and heat treated to improve wear resistance. The driving part 211 of the locking pin can adopt a motor-screw linear driving or electromagnetic driving structure, with a response time of less than 100 ms, ensuring that the locking pin can be quickly extended after the sensor detects abnormal load. The locking pin guide support seat 212 is made of impact-resistant nylon or aluminum alloy material to reduce weight and friction resistance. To avoid false triggering, the system sets a continuous judgment delay of 0.2 s for abnormal signals of the pressure sensor.

[0028] As shown in Figure 7 , the fork-shaped follow-up anti-falling device 22 is located below the battery and includes a telescopic fork assembly 221 and a follow-up mechanism 222; the telescopic fork assembly 221 is fixed to the sliding block of the follow-up mechanism 222, and can be telescoped in real time and can be driven by the follow-up mechanism 222 to rise or fall with the height of the battery. The telescopic fork assembly 221 includes an anti-falling fork arm 2211 and a telescopic driving device 2212 connected thereto; the follow-up mechanism 222 includes a lifting driver 2221 fixed to the frame and a screw screw assembly 2222 connected thereto; the fixed end of the telescopic driving device 2212 is fixed with the sliding block in the screw screw assembly 2222. The fork-shaped follow-up anti-falling device 22 is installed at the frame of the battery replacing robot, and the anti-falling fork arm 2211 is popped out by the telescopic driving device 2212 to actively prevent falling.

[0029] The follow-up mechanism 222 and the telescopic fork assembly 221 realize smooth linear motion through the sliding block-rail pair, and the rail gap is controlled within 0.05 mm. The telescopic driving device 2212 can be selected from an electric push rod or a small hydraulic cylinder to ensure that it can be extended in time to bear the impact load in the initial stage of battery falling. The front end of the anti-falling fork arm 2211 is provided with a non-slip pad layer to prevent hard collision between the battery bottom frame and the fork arm.

[0030] The telescopic driving device 2212 is drivingly connected with the frame of the battery replacing robot and can move up and down, mainly to follow the real-time change of the height of the battery to reduce the impact force when falling. When it is monitored that the battery is about to fall, the telescopic driving device 2212 extends the anti-falling fork arm 2211 to the lower side of the battery to provide upward supporting force.

[0031] In the application of large batteries, due to the large weight of the battery, the supporting force provided by the fork arm alone is insufficient, and a hydraulic supporting mechanism needs to be used to provide supporting force. The hydraulic supporting mechanism is arranged below the middle part of the anti-falling fork arm 2211, and when it is monitored that the ejection device is in action, the supporting end of the hydraulic supporting mechanism extends upward to act on the lower plane of the fork arm to improve the supporting strength; when the anti-falling fork arm 2211 is retracted, the hydraulic pressure is released, and the hydraulic supporting mechanism returns to the original position.

[0032] As shown in Figure 8 The vibration reduction unit 3 includes a driving unit 31, a telescopic positioning column 33 in driving connection with the driving unit 31, and a fixed bearing 32 for positioning the telescopic positioning column 33. When the monitoring unit 1 detects that the battery vibration amplitude or the deflection angle exceeds the set threshold, the telescopic positioning column 33 automatically extends and engages with the deep groove ball bearing in the limiting hole 201 on the battery outer frame 200 to suppress shaking and stabilize the battery posture; the monitoring unit 1 is used to calculate the overall stress distribution of the battery, and when any sensor signal disappears or the change rate exceeds the preset threshold, the anti-falling unit is triggered. The vibration reduction unit is provided with a plurality of limiting holes on the side of the battery close to the robot to reduce the shaking and vibration of the battery during replacement. The fixed bearing, generally a deep groove ball bearing, is installed in the hole. The positioning column is automatically popped out when the battery is grabbed, engaged with the inner diameter of the deep groove ball bearing, and the shaking is reduced. At the same time, this pop-out device also needs to be connected with the frame guide rail of the battery replacement robot and can move up and down with the battery. The driving part of the vibration reduction unit 3 drives the positioning column to align with the limiting hole on the battery. When the battery vibration amplitude is too large or there is a collision danger, the deflection angle is large, the telescopic positioning column can be freely telescopic, and the battery vibration and shaking are limited by the limiting hole.

[0033] The driving unit 31 of the vibration reduction unit is preferably a servo motor driven lead screw transmission structure, the maximum extension stroke of the telescopic positioning column 33 is 60 mm, and the positioning accuracy can reach ±0.2 mm. In order to prevent mechanical fatigue caused by frequent telescoping, the system is provided with a minimum action interval time, and the response sensitivity is automatically adjusted by monitoring the vibration frequency spectrum trend. The deep groove ball bearing adopts a self-lubricating structure to ensure smooth engagement with the positioning column. The positioning column telescoping signal and the anti-falling unit action signal are uniformly scheduled by the main control system to avoid interference between the two at the same time.

[0034] The battery replacement battery mainly includes battery cells and a battery outer frame 200, wherein the battery cells do not interact with the battery replacement robot, and the battery outer frame 200 of the battery replacement battery interacts with the battery replacement robot 100.

[0035] The battery replacement robot 100 includes a walking device, a lifting device, and a grabbing mechanism 101. The lifting device is used for lifting up and down, the walking device is used for translating the battery replacement robot in and out of the station, and the grabbing mechanism is used for grabbing and locking the battery.

[0036] Through the present application, the monitoring and anti-falling and vibration reduction during the battery replacement process are realized, the problem of lack of safety protection and insufficient state sensing of the conventional battery replacement robot during the battery replacement process is solved, and the safety of the battery during the whole process is ensured.

[0037] Pressure sensor, arranged at multiple contact points, when the battery is grabbed, the pressure sensor measurement value of multiple points should be in the range of P1~P2, when the abnormal signal appears, the anti-falling unit works automatically. Abnormal signal refers to: one or more signals disappear or change speed a is the limit value of the sensor value change speed in the normal battery replacement process in multiple tests, and then × correction coefficient is obtained.

[0038] Contact vibration sensor and non-contact vibration sensor are used to monitor the vibration of the battery replacement battery. The contact vibration sensor obtains the vibration spectrum of the battery in the battery replacement process, and the maximum value and the minimum value When the vibration exceeds the vibration spectrum limit value, the vibration reduction unit works, and the positioning column is actively popped out and engaged with the inner diameter of the deep groove ball bearing on the battery box shell to reduce the shaking.

[0039] The deformation sensor monitors the deformation of each point of the battery replacement robot during operation, and estimates the load condition.

[0040] The environmental temperature sensor measures the overall environmental temperature. The collision sensor is installed on the battery replacement robot frame, which monitors whether the battery replacement battery is subjected to collision through visual method; the visual camera is installed on the battery replacement station shell, which can identify the battery replacement panorama, and is used to determine which process the battery replacement is in.

[0041] Working process example: the battery replacement starts, the battery replacement robot is displaced above the battery, ready to grab the battery, the monitoring unit starts to work, and each data is monitored. When the battery is grabbed, the pressure sensor measures the value, at this time, if everything is normal, the value will not exceed the limit value a, if the value is abnormal, the battery replacement is stopped immediately, at this time, stopping the battery replacement will not cause serious consequences of battery falling.

[0042] If everything is normal, continue to grab and lift the battery, and when the battery is lifted to , the battery is completely decoupled from the battery replacement connector, and the vibration and shaking begin to be obvious. At this time, the contact vibration sensor and the non-contact vibration sensor start to measure the value, and when the value does not exceed f, the vibration reduction unit does not pop out. The non-contact vibration sensor is used to measure the angle of the battery shaking and deflection. When the deflection angle and shaking amplitude exceeds 4°, it is considered that the vibration is too large to affect the success rate of battery replacement, and the vibration reduction unit works and actively pops out the positioning column to combine with the fixed bearing on the battery to reduce the vibration.

[0043] Continue to lift the battery, the anti-falling unit and the vibration reduction unit are lifted synchronously with the battery replacement frame lifting mechanism, the battery is lifted to the top, the grabbing mechanism translates back to the station with the battery, and then descends in the station and engages with the base in the station to complete the battery replacement.

[0044] During system operation, the monitoring unit uploads the collected data to the main control system in real time, and the algorithm module performs multi-parameter fusion judgment. For example, when the pressure change rate and the vibration amplitude exceed the preset threshold value at the same time, the main control system preferentially triggers the action of the anti-falling unit; if only the vibration amplitude is out of limit, the vibration reduction unit is triggered. After each action, the system is automatically reset and the initial parameters are recalibrated to ensure the stability and repeatability of subsequent battery replacement operations. In addition, the system supports log recording function, all monitoring data and action events are automatically stored, which can be used for battery replacement process backtracking and maintenance analysis.

[0045] It should be noted that the monitoring, anti-falling and vibration reduction units in the embodiment are modularly designed, and the structure size and parameters can be flexibly adjusted according to the battery specifications, weight and battery replacement robot model. For extra-large batteries, the hydraulic support mechanism of the anti-falling unit can be upgraded to a double-cylinder synchronous structure to achieve higher support capacity; for light batteries, the system cost can be reduced by reducing the number of sensors and using lighter mechanisms. The system can be directly integrated without changing the overall layout of the original battery replacement station, and has good popularization and compatibility.

[0046] The application proposes a battery replacement equipment integrated with a battery replacement process monitoring and anti-falling device to solve the problems of falling, vibration and shaking that easily occur during battery transfer, to ensure the stability and safety of the battery replacement process, and to protect the battery in a mechanical anti-falling manner. The device also monitors parameters such as stress, vibration and deformation during the battery replacement process. This method is low in cost and high in reliability, and can be modified and improved on the existing battery replacement station without interfering with the existing battery replacement equipment.

[0047] Embodiment 2 Based on the same inventive concept, the application also provides a battery replacement equipment battery replacement process monitoring and anti-falling method, applied to the system as described in Embodiment 1, which comprises the following steps: S10: During the battery grabbing, lifting, translation and descending process, real-time collection of battery state data is performed by using pressure, vibration, deformation, temperature and speed sensors; S20: Comparison and analysis of the collected data are performed to determine whether there is stress imbalance, structural deformation or vibration deviation; S30: When the battery grabbing abnormality or falling trend is detected, the pop-out device of the anti-falling unit is driven to extend the anti-falling fork arm to the lower side of the battery, and the hydraulic support mechanism is simultaneously started to provide an upward supporting force; S40: When the vibration amplitude or deflection angle is out of limit, the vibration reduction unit is controlled to extend the positioning column and engage with the fixed bearing to stabilize the battery posture; S50: During the entire battery replacement process, the system continuously monitors and dynamically adjusts the anti-falling and vibration reduction response according to the real-time data.

[0048] Preferably, before triggering the anti-falling unit in step S30, the monitoring signal is subjected to multi-sensor consistency verification to exclude single-point false positives. Multi-sensor consistency verification includes three indicators: signal amplitude consistency, time synchronization, and signal trend consistency. The system calculates the sampling time difference Δt of each sensor, and if Δt≤20 ms and the amplitude change trend is consistent, it is determined to be consistent; if any condition is not met, the action is not triggered temporarily, and enters the "confirmation delay" state to prevent misjudgment.

[0049] Preferably, in step S40, the threshold of the deflection angle is set to 4°, and when the threshold is exceeded, the shock absorbing unit automatically extends the positioning column to maintain the stability of battery replacement.

[0050] In step S10, to ensure the integrity of the monitoring data, the system performs a zero-point calibration before the battery replacement starts, and takes the average of the 10-second data of each pressure, vibration, deformation, and temperature sensor as the reference value. The data acquisition module has a sampling frequency of 20-100 Hz to capture rapidly changing vibration signals. After the multi-channel sensor data collected is input to the control mainboard through the A / D module, it is processed by digital filtering (such as low-pass Butterworth filtering) and sliding average algorithm to reduce transient interference. The filtered data is displayed in real time on the monitoring interface and stored in a ring buffer queue for subsequent calculation and threshold determination.

[0051] In step S20, the data comparison module uses a multi-sensor data fusion algorithm to realize abnormality judgment. For pressure sensor signals, the system calculates the average load and load change rate in each sampling period; if a single sensor value deviates from the average load by ±15% or the change rate exceeds the reference value a×k (k is an empirical correction coefficient, taking 1.1-1.3), it is determined that the force is unbalanced. For vibration and sway signals, the control system extracts the main frequency component through fast Fourier transform (FFT), and when the main frequency amplitude exceeds the upper limit of the normal vibration spectrum or the deflection angle exceeds 4°, the vibration abnormality event is triggered. The system also uses Kalman filtering for multi-source data fusion, combined with the output of the speed sensor to determine whether the battery has abnormal acceleration, so as to identify the falling trend in advance.

[0052] In step S30, the control system sets a double protection mode for the driving logic of the anti-falling unit: ① When the monitoring signal shows that the battery acceleration exceeds 1.2 g and the duration is greater than 0.1 s, the anti-falling unit is triggered immediately; ② When three or more sensors simultaneously appear signal mutation or disconnection, the "redundancy protection" mode is triggered to extend the locking pin and the hydraulic support mechanism to act synchronously. After the anti-falling unit is executed, the main control system records the action timestamp and locks the execution state to avoid repeated pop-up due to false action. The hydraulic support mechanism controls the lifting speed through a proportional valve to not exceed 50 mm / s to buffer the impact of the falling battery.

[0053] In step S40, the control signal of the vibration reduction unit is sent by the master control system and dynamically adjusted according to the energy distribution of the real-time vibration spectrum. If the deflection angle is monitored to be between 2° and 4° but not exceeding the limit, the system enters the “early warning vibration suppression” state, and the positioning column is slightly extended (stroke 5-10 mm) to reduce vibration in advance; when the deflection angle is ≥4° or the vibration amplitude exceeds 80% of the upper limit of the vibration spectrum, the system enters the “strong vibration suppression” mode, and the positioning column is fully extended and locked. After the action is completed, the system automatically determines the stability, and when the vibration amplitude is lower than the set threshold value by 50% within 10 s, the positioning column is slowly retracted to the original position.

[0054] In step S50, to ensure real-time and fault tolerance, the master control system has a dynamic priority scheduling mechanism: the anti-falling action signal has higher priority than the vibration reduction action signal, and the two are interlocked to prevent misoperation conflicts. Both the monitoring and control modules use a dual-redundancy architecture, and when any module fails, the standby module takes over control within 50 ms. The system refreshes the sensor data every 100 ms and calculates the vibration spectrum and stress trend every 1 s, and if the results are consistent for three consecutive times, the action command is output. All monitoring data, determination events and action records are stored in a log file for subsequent maintenance and safety tracking. After the battery replacement is completed, the control system automatically executes the reset program, including retracting the anti-falling mechanism, resetting the positioning column, depressurizing the hydraulic system, and recalibrating the baseline of each sensor to ensure stable and reliable operation in the next battery replacement process.

[0055] All action thresholds in this embodiment can be parameterized and set through the upper computer software interface. Different battery weights and mechanical specifications can generate different parameter groups through automatic calibration programs, so as to adapt to multiple types of battery replacement equipment. To prevent data drift, the system automatically performs a full self-check and calibration every 24 hours and uploads the monitoring results to the maintenance server. This method is compatible with existing battery replacement station control protocols and can be implemented without additional hardware modifications.

[0056] The necessary technical contents not mentioned in the above embodiments all use existing public and available technologies, so they will not be described again.

[0057] The above is only an embodiment of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application is included in the scope of the claims of the present application.

Claims

1. A fall prevention system for monitoring the battery swapping process of a battery swapping device, characterized in that, include: Monitoring unit, fall protection unit, and vibration reduction unit; among which, The monitoring unit is installed on the gripping mechanism and frame of the battery swapping robot, and includes a pressure sensor, a contact vibration sensor, a non-contact vibration sensor, a deformation sensor, an ambient temperature sensor, a battery movement speed sensor, a collision sensor, and a vision camera. The anti-fall unit includes a hook anti-fall device installed on the upper part of the battery swapping robot and a fork-shaped follow-up anti-fall device fixed to the lower part of the battery swapping robot; The vibration reduction unit includes a telescopic positioning column and a fixed bearing. When the monitoring unit detects that the vibration amplitude or deflection angle of the battery exceeds the set threshold, the telescopic positioning column automatically extends and engages with the deep groove ball bearing in the limiting hole on the outer frame of the battery to suppress shaking and stabilize the battery posture. The monitoring unit is used to calculate the overall force distribution of the battery. When any sensor signal disappears or changes at a rate exceeding a preset threshold, the anti-fall unit is triggered.

2. The system according to claim 1, characterized in that, The fork-shaped follow-up anti-fall device includes: an anti-fall fork arm, a pop-out device, and a hydraulic support mechanism. The pop-out device is connected to the battery swapping robot frame via a guide rail and can move up and down. When the monitoring unit detects abnormal force on the battery or a tendency to fall, the pop-out device drives the anti-fall fork arm to extend under the battery, and the hydraulic support mechanism generates a reverse support force to prevent or mitigate the battery from falling.

3. The system according to claim 1, characterized in that, The non-contact vibration sensor uses laser ranging to calculate the vibration spectrum and deflection angle by detecting the vibration displacement of markers on the battery surface.

4. The system according to claim 1, characterized in that, The anti-fall fork arm consists of multiple sets of support rods, which are simultaneously driven by a pop-out device to form a multi-point support structure. The support points are linked with the hydraulic support mechanism to disperse the impact load.

5. The system according to claim 2, characterized in that, The hydraulic support mechanism maintains a pressure-released state when not in operation, and quickly establishes working pressure after detecting a fall signal to achieve instantaneous upward cushioning.

6. The system according to claim 1, characterized in that, The positioning column of the vibration reduction unit extends and retracts through an electronically controlled drive module. After extending, it forms a rotational engagement with the deep groove ball bearing, thereby maintaining the limit while allowing the battery to self-adjust slightly to prevent structural interference.

7. The system according to claim 1, characterized in that, The vision camera is installed on the outer shell of the battery swapping station to identify the stage and location status of the battery swapping process, and to fuse visual information with sensor data for anomaly detection.

8. A method for monitoring and preventing falls during the battery swapping process of a battery swapping device, applied to the system as described in claim 1, characterized in that, Includes the following steps: S10: During the battery grabbing, lifting, translation and descent process, sensors such as pressure, vibration, deformation, temperature and speed are used to collect battery status data in real time; S20: Compare and analyze the collected data to determine whether there is stress imbalance, structural deformation or vibration displacement. S30: When an abnormal battery gripping or downward trend is detected, the pop-out device of the anti-fall unit is controlled to drive the anti-fall fork arm to extend under the battery, and the hydraulic support mechanism is activated simultaneously to provide upward support force. S40: When the vibration amplitude or deflection angle exceeds the limit, the vibration reduction unit extends the positioning column and engages with the fixed bearing to stabilize the battery attitude. S50: Throughout the battery swapping process, the system continuously monitors and dynamically adjusts the anti-fall and vibration reduction responses based on real-time data.

9. The method according to claim 8, characterized in that, Before triggering the fall protection unit in step S30, the monitoring signal is checked for consistency across multiple sensors to eliminate false alarms from a single point.

10. The method according to claim 8, characterized in that, In step S40, the threshold for the deflection angle is set to 4°. When this threshold is exceeded, the vibration damping unit is automatically triggered to extend the positioning column to maintain the stability of the battery swapping.

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