Expandable intelligent battery charging and replacing cabinet system and control method thereof

Abstract

The invention provides an expandable intelligent battery charging and replacing cabinet system and a control method thereof, and relates to the field of new energy automobiles. Comprising a cabinet controller; the at least one charging unit group is connected with one independent communication bus; each charging unit group comprises a charging controller and at least one independent charging module; each independent charging module comprises a battery management controller and a charger; the battery management controller is used for collecting parameter information of the battery in the independent charging module and sending the parameter information to the corresponding charging controller; the charger is used for charging the battery according to an instruction of the charging controller; the battery type identification unit is used for identifying the type of the battery arranged in the independent charging module; and the charging controller is configured to match and call corresponding charging parameters to control the charger to execute charging according to the identified battery type. According to the system, flexible configuration of the charging capacity, compatible charging of multiple types of batteries and sustainable remote optimization of the system are realized.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicles, and more specifically, to an expandable intelligent charging and swapping cabinet system and its control method. Background Technology

[0002] With the rapid increase in the market penetration rate of new energy vehicles, users' demand for energy replenishment efficiency is growing. Traditional charging methods, limited by battery charging time, cannot meet users' needs for rapid energy replenishment. Battery swapping, by directly replacing the vehicle's battery, can significantly shorten replenishment time, improve user experience, and help balance grid load, thus becoming one of the important energy replenishment methods.

[0003] In existing technologies, intelligent battery swapping cabinets are widely used due to their small footprint and ease of use. However, most current battery swapping cabinets suffer from the following limitations: First, the system architecture is fixed, and the number of charging bays cannot be flexibly increased or decreased according to actual business needs, resulting in idle resources during periods of low demand and an inability to quickly expand capacity during periods of high demand, leading to insufficient investment efficiency and operational flexibility. Second, the market offers a variety of electric vehicle battery specifications, models, and communication protocols, and existing battery swapping cabinets often only serve a single or a few specific types of batteries, resulting in poor versatility. Furthermore, the system's control logic and charging strategies are fixed, making it impossible to iterate and optimize remotely, and thus difficult to adapt to the rapid development of battery technology and adjustments in operational strategies. Summary of the Invention

[0004] The purpose of this invention is to provide an scalable intelligent charging and swapping cabinet system and its control method, which has high scalability, can automatically identify multiple battery types and adapt charging parameters, and supports remote upgrades, realizing flexible configuration of charging and swapping capacity, compatible charging of multiple battery types, and continuous remote optimization of the system.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A scalable intelligent charging and swapping cabinet system, comprising: Cabinet controller; At least one charging unit group, each of the charging unit groups being connected to an independent communication bus; Each of the charging unit groups includes a charging controller and at least one independent charging module; the charging controller is communicatively connected to the cabinet controller via its own communication bus; Each of the independent charging modules includes a battery management controller and a charger; the battery management controller is used to collect parameter information of the battery placed in the independent charging module and send the parameter information to the corresponding charging controller; the charger is connected to the charging controller and is used to charge the battery according to the instructions of the charging controller; The system also includes a battery type identification unit for identifying the type of battery placed in the independent charging module; the charging controller is configured to match and call the corresponding charging parameters to control the charger to perform charging based on the identified battery type.

[0006] Furthermore, in this invention, the battery type identification unit includes N physical contact sensors disposed within each of the independent charging modules, wherein N is an integer greater than or equal to 2; the on / off state of each physical contact sensor forms an N-bit binary code; the charging controller is configured to identify the type of the battery based on the binary code.

[0007] Furthermore, in this invention, the battery is provided with a touch portion corresponding to at least a portion of the physical contact sensors; when the battery is placed into the independent charging module, the touch portion triggers the corresponding physical contact sensor to turn on, while the physical contact sensors not corresponding to the touch portion remain disconnected.

[0008] Furthermore, in this invention, the charging controller is configured to execute the following charging control process: Receive battery parameter information from the battery management controller; After determining that the battery parameter information is normal, a charging availability signal is sent to the cabinet controller; Upon receiving a charging start command from the cabinet controller, the high-voltage power supply circuit is turned on, and a charging enable signal and a charging demand based on the matched charging parameters are sent to the charger.

[0009] Furthermore, in this invention, the cabinet controller is configured as follows: Receive and process charging availability signals and battery information from each of the charging controllers; In response to external operation commands, the charging start command and the compartment door control command are sent to the corresponding charging controller.

[0010] Furthermore, in this invention, within the same charging unit group, the charging controller and the chargers of each independent charging module use independent communication identifiers for data interaction.

[0011] Furthermore, the present invention also includes a remote communication module, which is connected to each of the communication buses and is used to upload system data to the cloud platform and support remote firmware upgrades of the cabinet controller and / or the charging controller through the communication buses.

[0012] Furthermore, in this invention, the system supports expanding or reducing the system charging capacity by increasing or decreasing the number of the charging unit groups and the corresponding number of the communication buses.

[0013] A battery type identification method, applied to the aforementioned scalable intelligent charging and swapping cabinet system, includes: Based on the position of the contact part placed on the battery, multiple physical contact sensors located in the independent charging module form a specific combination of on / off states; The on / off state combination is read by the charging controller and mapped to the corresponding battery type code. The pre-stored set of charging parameters corresponding to the battery type is called according to the battery type code.

[0014] A charging control method, applied to the aforementioned scalable intelligent charging and swapping cabinet system, includes: After confirming that the battery status in the independent charging module it manages is normal, the charging controller sends a charging available signal to the cabinet controller. When the cabinet controller receives the charging available signal and confirms that there is a charging start request, it sends a charging start command to the charging controller. In response to the charging start command, the charging controller performs a power-on operation on the high-voltage power supply circuit and sends a charging enable signal and charging demand to the charger. The charger performs a charging operation on the battery according to the charging demand.

[0015] The present invention has at least the following advantages or beneficial effects: This invention employs a "1+N" distributed architecture, where a cabinet controller is connected to at least one charging unit group, with each charging unit group having its own independent communication bus. This enables modular expansion of the system's charging capacity and independent communication management. When capacity expansion is needed, only the corresponding charging unit groups and buses need to be added, without refactoring the core control logic, significantly improving the flexibility and maintainability of system deployment. By setting a charging controller and at least one independent charging module within each charging unit group, and each independent charging module containing a battery management controller and a charger, distributed and refined control of the charging process for multiple batteries can be achieved. The charging controller acts as the coordinating unit within the group, the battery management controller is responsible for real-time acquisition of battery parameters, and the charger is responsible for executing charging. This division of labor and cooperation ensures the safety and efficiency of the charging process and reduces the risk of single-point failures. By setting a battery type identification unit and enabling the charging controller to match and call the corresponding charging parameters based on the identified battery type, it can automatically and accurately identify batteries of different specifications and models and automatically adapt their optimal charging strategies. This achieves compatible charging for multiple battery types, improves the system's versatility and user convenience, and avoids charging safety hazards caused by parameter mismatches. This application utilizes a modular and scalable "1+N" distributed control architecture, combined with a hardware-based automatic battery type identification mechanism, to achieve flexible configuration of charging and swapping capacity, compatible charging of multiple battery types, and continuous remote optimization of the system. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 A structural block diagram of an expandable intelligent charging and swapping cabinet system provided for the application embodiments; Figure 2 A structural diagram of an expandable intelligent charging and swapping cabinet system provided in one embodiment of the application; Figure 3 A charging flowchart of an scalable smart charging and swapping cabinet system provided in one embodiment of the application. Detailed Implementation

[0018] 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 embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention. Example

[0020] Please refer to Figure 1 The figure shown is a structural schematic diagram of an expandable intelligent charging and swapping cabinet system in an embodiment of the present invention. This embodiment provides a scalable intelligent charging and swapping cabinet system. The system uses a cabinet controller as the core management unit and connects at least one charging unit group via multiple independent communication buses (e.g., CAN bus), forming a "1+N" distributed control architecture. Each charging unit group includes a charging controller and at least one independent charging module. Each charging unit group has its own dedicated communication bus, thus forming a physically and logically independent control unit. The independent charging module, as the execution unit, includes a battery management controller (BMS controller) and a charger. The battery management controller is responsible for collecting real-time parameters (such as voltage, temperature, SOC, etc.) of the batteries placed in the compartment and reporting them to the charging controller of its group via an internal communication path. After the charging controller summarizes the information and determines that everything is normal, it collaborates with the cabinet controller to ultimately control the charger to perform the charging operation. The core advantage of this architecture lies in its scalability: the total charging capacity of the system can be linearly expanded or reduced by simply adding or removing charging unit groups and their dedicated communication buses without modifying the core control logic, greatly improving the flexibility of system deployment and the economy of investment.

[0021] In this embodiment, the system further includes a battery type identification unit, which preferably employs a hardware contact identification scheme. Specifically, N (N≥2) physical contact sensors (such as microswitches, probe contacts, etc.) are set within each independent charging module. The on / off state of each sensor forms an N-bit binary code. Correspondingly, specific positions and numbers of contact parts, such as protrusions, are pre-set on the casings of different battery types. When a battery is correctly placed into the charging module, its contact part will activate the corresponding sensor, while uncontacted sensors remain disconnected. The charging controller can uniquely determine the battery type by reading this binary code. For example, with 3 sensors (N=3), theoretically, 2³ - 1 = 7 battery types can be distinguished (excluding the completely off state, which may represent no battery or a malfunction).

[0022] This solution does not rely on the battery's communication protocol, ensuring reliable identification and rapid response. The charging controller has pre-stored the optimal charging parameter set (including required voltage, protection voltage, required current, charging algorithm, etc.) corresponding to different battery type codes. After identification, it automatically calls the matching parameters to control the charger, achieving "plug and play, identify and charge instantly," greatly improving the system's compatibility and charging safety for different brands and models of batteries.

[0023] The system's charging control process is completed collaboratively by the charging controller and the cabinet controller. After confirming that the battery parameters are normal (e.g., voltage within a reasonable range, no serious alarms) through the battery management controller, the charging controller sends a charging availability signal to the cabinet controller. The cabinet controller, acting as the human-machine interface and centralized dispatch center, receives and processes signals and battery information from each charging controller. Upon receiving a charging start request initiated by a user via the interface or QR code, it issues a charging start command to the corresponding charging unit group's charging controller. Upon receiving the command, the charging controller first activates the relay in the high-voltage power supply circuit, then sends a charging enable signal and the specific charging requirements based on the matched charging parameters to the charger, initiating the charging process. This hierarchical control logic is clear and responsibilities are well-defined, ensuring the orderly and reliable operation of the system.

[0024] As a preferred implementation, to ensure the reliability of communication when multiple independent charging modules within the same charging unit group are working in parallel and to avoid command and data conflicts, the communication between the charging controller and each charger within the group uses independent communication identifiers (such as CAN message IDs). This point-to-point virtual channel isolation design ensures the independence of each charging process and the accuracy of control signals.

[0025] As a preferred implementation method, to further enhance the system's intelligence and lifecycle management capabilities, the system also integrates a remote communication module. This module is preferably a Telematics Box (TBOX), connected to all communication buses, and performs two core functions: first, as a data gateway, it uploads all battery status, charging process data, and fault information within the cabinet to the cloud management platform in real time, supporting remote monitoring and big data analysis; second, as an upgrade agent, it supports remote firmware upgrades (OTA) to the cabinet controller and / or charging controller via independent communication buses. Since each charging unit group is located on an independent communication bus, the TBOX can perform partitioned and targeted upgrades of controllers on different buses without interference. This allows the system to continuously update charging strategies, optimize control algorithms, fix software defects, or adapt to new battery types without hardware modifications, achieving system function iteration and performance optimization, significantly extending the product's effective lifecycle and reducing maintenance costs.

[0026] In one specific embodiment, reference is made to Figure 2 This paper illustrates the system architecture of a basic embodiment of the present invention. The system includes a cabinet controller, two charging unit groups (i.e., N=2), and a remote communication module. Each charging unit group is connected to the cabinet controller via an independent communication bus (e.g., CAN-1, CAN-2). Each charging unit group contains a charging controller and three independent charging modules (i.e., each charging unit group manages three charging bays). Each independent charging module contains a BMS controller and a charger, capable of simultaneously charging and swapping six batteries. The BMS controller collects battery parameters through a battery-side communication interface (e.g., battery CAN or daisy chain). The charging controller communicates with its three BMS controllers and three chargers via an internal bus (which can be another CAN or a proprietary protocol). The cabinet controller is also connected to a user interaction display screen. The remote communication module accesses all communication buses and connects to a cloud network.

[0027] In this embodiment, the battery type identification unit consists of three physical contact sensors (not shown in the figure, e.g., S1, S2, S3) installed in each independent charging module compartment. When the contact points touch, an independent conductive loop is formed. The charging controller can identify the conductive state 1 and the floating state 0 by collecting the voltage of the corresponding contact points. Therefore, the three physical contact sensors can distinguish a total of 7 battery types, represented by binary 0000 0111. Assuming that the contact part of a certain type A battery is designed to only contact sensors S1 and S3, the binary code generated after insertion is 101 (S1=1 on, S2=0 off, S3=1 on), corresponding to the decimal value 5. The charging controller pre-stores the charging parameter set A corresponding to code 5. When code 101 is identified, parameter set A is automatically called. Generally, if N sensors are set, the number S of effective battery types that the system can distinguish is 2^ N -1 type (excluding all 0 states). Based on the identified different battery types, the charging controller matches the corresponding charging parameters (required voltage, protection voltage, required current, etc.) to complete the charging process.

[0028] Based on the actual required number of identifiable types, the number N of electric shock switches can be adjusted accordingly. The relationship between the total number of identifiable types S and N is as follows:

[0029] The recognition capacity can be flexibly adjusted by increasing or decreasing the N value, and the formula expresses the quantitative relationship between the recognition capacity and the hardware configuration.

[0030] Charging control process combined Figure 3 Explanation. Taking charging a single battery as an example: First, the BMS controller continuously collects battery parameters and reports them to the charging controller. The charging controller determines that the parameters are normal (no abnormal battery voltage, inability to collect voltage, etc.), and then sends a charging availability signal (charge_avaliable) to the cabinet controller. Upon receiving the charge_avaliable signal, if the cabinet controller detects a charging start switch signal, it sends a charging start signal (charge_start) back to the charging controller. The charging controller then activates the high-voltage circuit relay and sends a charging enable signal (charge_enable) and the charging request to the charger to begin the charging process. The charger executes the charging operation based on this request. Throughout the entire process, the charging controller and the three chargers communicate using three different CAN IDs to ensure accurate delivery of instructions.

[0031] Based on the power swapping requirements, the number of charging cabinet groups can be increased or decreased, and the number of CAN buses can be increased or decreased simultaneously. Each charging cabinet group is independently distributed on each CAN bus, and all CAN bus channels are connected to the terminal TBOX, enabling independent OTA upgrades of the controller on that CAN bus and achieving optimized iterations of the charging and swapping functions. If it is necessary to expand from the current 6 compartments (2 groups × 3 compartments) to 12 compartments, only two identical charging unit groups and their corresponding two new communication buses need to be added, and connected to the cabinet controller and remote communication module. The cabinet controller software only needs to recognize the newly added buses and logic units, without the need to refactor the core control program.

[0032] This application also provides a battery type identification method applied to the above-described system, comprising the following steps: Based on the position of the contact part placed on the battery, multiple physical contact sensors located in the independent charging module form a specific combination of on / off states; The on / off state combination is read by the charging controller and mapped to the corresponding battery type code. The pre-stored set of charging parameters corresponding to the battery type is called according to the battery type code.

[0033] This method is based on hardware contact recognition. It generates a unique on / off state combination code through the interaction between the physical contact points on the battery and the sensor array within the charging module. The charging controller reads this code and maps it to a specific battery type identifier via table lookup or calculation, then automatically invokes the standardized charging parameter set associated with that type. This method is simple and efficient, directly converting physical contact information into executable control parameters, which is key to achieving adaptive charging for multiple battery types.

[0034] This application also provides a charging control method for the above-described system, comprising the following steps: After confirming that the battery status in the independent charging module it manages is normal, the charging controller sends a charging available signal to the cabinet controller. When the cabinet controller receives the charging available signal and confirms that there is a charging start request, it sends a charging start command to the charging controller. In response to the charging start command, the charging controller performs a power-on operation on the high-voltage power supply circuit and sends a charging enable signal and charging demand to the charger. The charger performs a charging operation on the battery according to the charging demand.

[0035] This method embodies a "detection-request-execution" safety control logic. The charging controller, acting as the local "execution manager," is responsible for verifying battery status and determining charging readiness; the cabinet controller, acting as the central "dispatch commander," is responsible for receiving user instructions and authorizing activation. The two work together through explicit signal interaction (charging availability signal, charging start command). After receiving authorization, the charging controller systematically executes operations such as high-voltage power-on, parameter distribution, and charging initiation. This method is clearly hierarchical and effectively prevents misoperation through a dual confirmation mechanism, ensuring the safety and controllability of the charging and swapping process.

[0036] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An expandable intelligent charging and swapping cabinet system, characterized in that, include: Cabinet controller; At least one charging unit group, each of the charging unit groups being connected to an independent communication bus; Each of the charging unit groups includes a charging controller and at least one independent charging module; the charging controller is communicatively connected to the cabinet controller via its own communication bus; Each of the independent charging modules includes a battery management controller and a charger; the battery management controller is used to collect parameter information of the battery placed in the independent charging module and send the parameter information to the corresponding charging controller; the charger is connected to the charging controller and is used to charge the battery according to the instructions of the charging controller; The system also includes a battery type identification unit for identifying the type of battery placed in the independent charging module; the charging controller is configured to match and call the corresponding charging parameters to control the charger to perform charging based on the identified battery type.

2. The expandable intelligent charging and swapping cabinet system according to claim 1, characterized in that, The battery type identification unit includes N physical contact sensors disposed in each of the independent charging modules, wherein N is an integer greater than or equal to 2; the on / off state of each physical contact sensor forms an N-bit binary code; the charging controller is configured to identify the type of battery based on the binary code.

3. The expandable intelligent charging and swapping cabinet system according to claim 2, characterized in that, The battery is provided with a touch portion corresponding to at least a portion of the physical contact sensors; when the battery is placed into the independent charging module, the touch portion triggers the corresponding physical contact sensor to turn on, and the physical contact sensors not corresponding to the touch portion remain disconnected.

4. The expandable intelligent charging and swapping cabinet system according to claim 1, characterized in that, The charging controller is configured to execute the following charging control procedure: Receive battery parameter information from the battery management controller; After determining that the battery parameter information is normal, a charging availability signal is sent to the cabinet controller; Upon receiving a charging start command from the cabinet controller, the high-voltage power supply circuit is turned on, and a charging enable signal and a charging demand based on the matched charging parameters are sent to the charger.

5. The expandable intelligent charging and swapping cabinet system according to claim 1 or 4, characterized in that, The cabinet controller is configured as follows: Receive and process charging availability signals and battery information from each of the charging controllers; In response to external operation commands, the charging start command and the compartment door control command are sent to the corresponding charging controller.

6. The scalable intelligent charging and swapping cabinet system according to claim 1, characterized in that, Within the same charging unit group, the charging controller and the chargers of each independent charging module use independent communication identifiers to exchange data.

7. The expandable intelligent charging and swapping cabinet system according to claim 1, characterized in that, It also includes a remote communication module, which is connected to each of the communication buses and is used to upload system data to the cloud platform and support remote firmware upgrades of the cabinet controller and / or the charging controller through the communication buses.

8. The expandable intelligent charging and swapping cabinet system according to claim 1, characterized in that, The system supports expanding or reducing the system's charging capacity by increasing or decreasing the number of the charging unit groups and the corresponding number of communication buses.

9. A method for identifying battery type, applied to an expandable intelligent charging and swapping cabinet system as described in any one of claims 1-3, characterized in that, Includes the following steps: Based on the position of the contact part placed on the battery, multiple physical contact sensors located in the independent charging module form a specific combination of on / off states; The on / off state combination is read by the charging controller and mapped to the corresponding battery type code. The pre-stored set of charging parameters corresponding to the battery type is called according to the battery type code.

10. A charging control method, applied to the scalable intelligent charging and swapping cabinet system as described in any one of claims 1-8, characterized in that, Includes the following steps: After confirming that the battery status in the independent charging module it manages is normal, the charging controller sends a charging available signal to the cabinet controller. When the cabinet controller receives the charging available signal and confirms that there is a charging start request, it sends a charging start command to the charging controller. In response to the charging start command, the charging controller performs a power-on operation on the high-voltage power supply circuit and sends a charging enable signal and charging demand to the charger. The charger performs a charging operation on the battery according to the charging demand.

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