Heavy truck battery replacement system

Abstract

The invention provides a heavy truck battery replacing system, and relates to the technical field of battery replacing systems.The heavy truck battery replacing system comprises a control room, a battery bin and battery replacing equipment, a battery replacing channel is arranged between the control room and the battery bin, the battery replacing equipment is erected above the control room and the battery bin, and the control room comprises a control module; and the control module is in communication connection with the battery compartment and the battery replacement equipment, and the control module is used for controlling the battery replacement equipment to replace a battery between the to-be-treated vehicle and the battery compartment according to the state of the to-be-treated vehicle in the battery replacement channel. According to the invention, the battery of the heavy truck is quickly replaced, so that a large amount of time consumed in a charging link is avoided, and the energy complementing efficiency of the vehicle can be effectively improved.

Description

Technical Field

[0001] This invention relates to the field of battery swapping system technology, and more specifically, to a heavy-duty truck battery swapping system. Background Technology

[0002] Driven by the energy transition wave, the electric vehicle industry has achieved rapid development, gradually extending from large-scale adoption in the passenger vehicle sector to the commercial vehicle sector, becoming a core direction for the green transformation of the transportation industry. Among them, electric heavy-duty trucks, as a key sub-category of commercial vehicle electrification, have seen their penetration rate continue to rise due to their advantages of low emissions and low operating costs, and are widely used in closed and semi-closed scenarios such as port collection and distribution, mining transportation, and urban logistics.

[0003] In related technologies, the charging time of traditional charging mode may be as long as several hours, which is difficult to meet the demand of heavy trucks for efficient charging during transportation. This results in a lot of time being spent in the charging process when the vehicle is out of service, affecting the vehicle's charging efficiency. Summary of the Invention

[0004] The problem addressed by this invention is how to improve the refueling efficiency of vehicles.

[0005] To address the above problems, this invention provides a heavy-duty truck battery swapping system.

[0006] In a first aspect, the present invention provides a heavy-duty truck battery swapping system, including a control room, a battery compartment, and battery swapping equipment. A battery swapping channel is provided between the control room and the battery compartment. The battery swapping equipment is mounted above the control room and the battery compartment. The control room includes a control module, which is communicatively connected to both the battery compartment and the battery swapping equipment. The control module is used for: Based on the status of the vehicle to be processed in the battery swapping channel, the battery swapping equipment is controlled to replace the battery between the vehicle to be processed and the battery compartment.

[0007] Optionally, controlling the battery swapping equipment to replace the battery between the vehicle to be processed and the battery compartment based on the status of the vehicle in the battery swapping channel includes: Obtain the vehicle information of the vehicle to be processed; If the vehicle information is the same as the preset battery information of the vehicle to be replaced, then the battery swapping device is controlled to replace the battery between the vehicle to be processed and the battery compartment. Otherwise, a message indicating that battery swapping is not allowed will be generated.

[0008] Optionally, the system further includes a 3D vision module, which is positioned above the battery swapping channel to acquire the location of the vehicle-side battery on the vehicle to be processed and send the vehicle-side battery location to the control module; controlling the battery swapping equipment to replace the battery between the vehicle to be processed and the battery compartment includes: Based on the received vehicle-side battery location, determine whether the location of the vehicle to be processed meets the battery swapping requirements; If so, the battery swapping device is controlled to swap batteries between the vehicle to be processed and the battery compartment; If not, a re-parking prompt will be generated.

[0009] Optionally, the battery compartment includes a buffer position and a mounting module. The buffer position is located at one end of the battery compartment near the battery swapping channel, and multiple mounting modules are sequentially arranged within the battery compartment along a first direction away from the battery swapping channel. Controlling the battery swapping equipment to replace the battery between the vehicle to be processed and the battery compartment includes: Based on the location of the vehicle-side battery, the battery swapping device is controlled to grab the depleted battery from the vehicle to be processed and place it in the buffer position, and the fully charged battery from the rack module is grabbed and placed in the vehicle-side battery position.

[0010] Optionally, controlling the battery swapping device to grab the depleted battery from the vehicle to be processed and place it into the buffer position based on the location of the vehicle-end battery includes: Send a battery unlock command to the vehicle to be processed; Once the vehicle to be processed is successfully unlocked, the battery swapping robot controlling the battery swapping equipment grabs the depleted battery from the vehicle-side battery location and places it in the buffer position.

[0011] Optionally, the step of grabbing the fully charged battery of the loader module to the vehicle-end battery position includes: Obtain the battery position at the end of the fully charged battery compartment; The fully charged battery is retrieved from the warehouse battery location to the vehicle battery location, and a battery locking command is sent to the vehicle to be processed. Once the vehicle to be processed is successfully locked, a battery swap completion notification will be generated.

[0012] Optionally, the loader module includes a battery storage unit, a charging unit, and a dual-channel charging gun. The battery storage unit is used to store the battery, the charging unit is used to charge the battery in the battery storage unit, and the dual-channel charging gun is used to charge vehicles outside the station.

[0013] Optionally, the system also includes a fire protection subsystem, which includes fire detectors, manual fire alarm buttons, fire audible and visual alarm buttons, and a fire central controller. The fire detectors and manual fire alarm buttons are respectively installed in preset locations in the control room and the battery compartment. The fire central controller is installed in the control room and is communicatively connected to the fire detectors and the manual fire alarm buttons.

[0014] Optionally, the system further includes a station interaction subsystem, which is used for: The indicator light color is displayed according to the channel status of the battery swapping channel and the preset status matching rule, wherein the status matching rule includes a one-to-one correspondence between the channel status and the indicator light color; And / or, the station interaction subsystem is also used to broadcast system prompts via loudspeakers.

[0015] Optionally, the system further includes at least one first housing, a second housing, and a maintenance room. The battery compartment includes a buffer position and a mounting module. The maintenance room is used to house the control room. One first housing is used to house the buffer position. The other first housings are respectively equipped with the mounting modules. The second housing is located above the battery swapping channel between the maintenance room and the first housing. The first housings, the second housings, and the maintenance room are sequentially connected and interconnected. The first housing with the buffer position is located near the battery swapping channel. The battery swapping robot's battery swapping track is located within the channel formed by the first housing, the second housing, and the maintenance room.

[0016] The beneficial effects of the heavy-duty truck battery swapping system of this invention are as follows: Through the layout and intelligent control of the control room, battery compartment, and battery swapping equipment, it effectively solves the problems of long charging time and reduced charging efficiency in traditional charging modes. A battery swapping channel is set between the control room and the battery compartment, adapting to the heavy-duty truck battery swapping operation route. The battery swapping equipment is installed overhead, significantly optimizing space utilization while making the battery swapping operation more precise and efficient. The control module communicates and links with the battery compartment and battery swapping equipment, and can autonomously control the battery swapping equipment to complete the battery replacement between the vehicle and the battery compartment based on the status of the vehicle to be processed in the channel. The entire process requires no manual intervention, significantly reducing the heavy-duty truck charging time, completely eliminating the time loss from charging during downtime, and significantly improving vehicle turnover efficiency and overall transportation benefits, thus meeting the core requirement of efficient charging for heavy-duty truck transportation. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a heavy-duty truck battery swapping system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the carrier module according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the station type expansion according to an embodiment of the present invention.

[0018] Explanation of reference numerals in the attached figures: 1-Control room; 2-Battery compartment; 21-Buffer position; 22-Carrier module; 221-Battery storage unit; 222-Charging unit; 223-Dual charging gun; 3-Battery swapping equipment; 4-Battery swapping channel; 5-3D vision module; 6-Maintenance room; 7-First enclosure; 8-Second enclosure. Detailed Implementation

[0019] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Although some embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the accompanying drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0020] It should be understood that the various steps described in the method embodiments of the present invention may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this respect.

[0021] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this invention are used only to distinguish different devices, modules, or units, and are not intended to limit the order of functions performed by these devices, modules, or units or their interdependencies.

[0022] It should be noted that the terms "a" and "a plurality of" used in this invention are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0023] The names of the messages or information exchanged between the multiple devices in the embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of these messages or information.

[0024] In related technologies, traditional fast charging mostly adopts a fixed charging mode with no flexible adjustment space for the charging rate. Affected by factors such as the battery management system's temperature control protection, constant current and constant voltage charging characteristics, and extreme temperature and humidity, the actual charging time often lasts 1 to 2 hours. Heavy-duty trucks, as the core carriers of logistics transportation, have significant characteristics of continuous and high-frequency transportation operations. The need for rapid charging and immediate departure during transportation is particularly urgent. However, the long-term charging limitation of the fixed charging mode makes it difficult to match the actual operational charging needs of heavy-duty trucks. This problem directly leads to heavy-duty trucks having to stop for extended periods while waiting for charging during transportation, significantly compressing effective transportation time, disrupting vehicle turnover rhythm, and severely impacting the charging efficiency of heavy-duty trucks, making it difficult to meet the core requirements of the logistics industry for transportation timeliness and operational efficiency.

[0025] To address the problems existing in the aforementioned related technologies, embodiments of the present invention provide a heavy-duty truck battery swapping system.

[0026] like Figure 1 As shown in the figure, an embodiment of the present invention provides a heavy truck battery swapping system, including a control room 1, a battery compartment 2, and a battery swapping device 3. A battery swapping channel 4 is provided between the control room 1 and the battery compartment 2. The battery swapping device 3 is mounted above the control room 1 and the battery compartment 2. The control room 1 includes a control module, which is communicatively connected to the battery compartment 2 and the battery swapping device 3.

[0027] Specifically, the control room 1 and the battery compartment 2 are symmetrically distributed, with a dedicated battery swapping channel 4 reserved between them. This channel not only provides precise entry, exit, and parking space for heavy trucks waiting to have their batteries swapped, but also achieves operational compatibility between vehicles and battery swapping equipment 3 through reasonable planning, ensuring the orderly progress of the battery swapping process. The battery swapping equipment 3 is installed above the control room 1 and the battery compartment 2. The high-altitude layout saves ground space and ensures that the battery swapping action covers the entire range of the battery swapping channel 4, avoiding interference with vehicles and ground facilities. Its main body adopts a battery swapping robot with a rigid connection design, which can accurately complete a series of operations such as battery grabbing, transfer, and installation. Control room 1 serves as the command center for the entire system, with a built-in core control module. This module establishes a stable communication connection with battery compartment 2 and battery swapping equipment 3 through the internal network of the battery swapping station. On the one hand, it can monitor the battery status of each compartment in battery compartment 2 in real time (such as power, location, charging progress, etc.). On the other hand, it can issue precise control commands such as grabbing and installation to battery swapping equipment 3, while receiving operational data fed back by battery swapping equipment 3, forming a closed-loop control of "monitoring-command-execution-feedback". This ensures the automation and precision of the entire battery swapping process, effectively improving battery swapping efficiency and safety.

[0028] The control module is used for: Based on the status of the vehicle to be processed in the battery swapping channel 4, the battery swapping device 3 is controlled to swap batteries between the vehicle to be processed and the battery compartment 2.

[0029] Specifically, the control module, acting as the command unit, is responsible for the overall scheduling and precise control of the battery swapping process. The control module can acquire key status information of the vehicles to be processed in real time, including whether the vehicle is legitimate (verified by RFID technology to ensure consistency of the Vehicle Identification Number (VIN)), whether it is accurately parked at the designated battery swapping location (confirmed by dot-matrix laser positioning and visual scanning), and whether the vehicle has completed power-off and battery unlocking preparations. After confirming that the vehicle meets the battery swapping conditions, the control module first issues precise operating instructions to the battery swapping device 3, guiding it to move to the battery installation location of the vehicle to be processed. Through a rigid connection transmission structure, it stably grabs the depleted battery from the vehicle and transfers it to an empty slot or fixed buffer within the battery compartment 2 according to a preset path. Position 21; Subsequently, based on the battery status data in battery compartment 2 (such as the charging progress and health status of batteries in each compartment), the control module selects the fully charged compatible batteries, sends power-taking and installation instructions to the battery swapping device 3, drives the battery swapping device 3 to accurately grab the fully charged battery and transfer it to the battery installation position of the vehicle to be processed, and completes the battery alignment and installation; after the battery is installed in place, the control module further coordinates the battery swapping device 3 and the vehicle control system to complete the battery locking action, and receives the battery swapping completion signal from the device, and finally confirms the closed loop of the battery replacement process, ensuring that the battery swapping process is efficient, accurate and safe, and realizing fully automated control of battery replacement between the vehicle to be processed and battery compartment 2.

[0030] In this embodiment, the layout and intelligent control of the control room 1, battery compartment 2, and battery swapping equipment 3 effectively solve the problems of long charging time and reduced charging efficiency in traditional charging modes. A battery swapping channel 4 is set between the control room 1 and the battery compartment 2 to adapt to the battery swapping operation route of heavy trucks. The battery swapping equipment 3 is installed above the two, which greatly optimizes space utilization and makes the battery swapping operation more precise and efficient. The control module communicates and links with the battery compartment 2 and the battery swapping equipment 3. It can autonomously control the battery swapping equipment 3 to complete the battery replacement between the vehicle and the battery compartment 2 according to the status of the vehicle to be processed in the channel. The whole process does not require manual intervention, which greatly reduces the charging time of heavy trucks, completely eliminates the time loss of charging during downtime, significantly improves vehicle turnover efficiency and overall transportation efficiency, and meets the core requirement of efficient charging for heavy truck transportation.

[0031] Optionally, such as Figure 1 As shown, controlling the battery swapping device 3 to swap batteries between the vehicle to be processed and the battery compartment 2 based on the status of the vehicle in the battery swapping channel 4 includes: Obtain the vehicle information of the vehicle to be processed; If the vehicle information is the same as the preset battery information of the vehicle to be replaced, then control the battery swapping device 3 to replace the battery between the vehicle to be processed and the battery compartment 2. Otherwise, a message indicating that battery swapping is not allowed will be generated.

[0032] In this optional embodiment, during the battery swapping process initiation phase, the control module first acquires vehicle information of the vehicle to be processed through devices such as the RFID reader / writer and RFID receiver of the linkage station interaction system. The core information is the vehicle's unique identification number (VIN). Simultaneously, it can collect related information such as vehicle model and battery specifications to ensure the completeness and accuracy of information collection. Subsequently, the control module comprehensively compares the real-time acquired vehicle information with a pre-set list of vehicles to be swapped. This list includes key data such as registered and filed compliant vehicle VINs, compatible vehicle models, and corresponding battery parameters. The comparison process focuses on the consistency and matching degree of information, with a key focus on verifying the legality of the vehicle's identity and battery compatibility. If the comparison confirms that the two are completely consistent, it indicates that the vehicle is qualified for battery swapping and the battery specifications are compatible. The control module immediately issues an operation to the battery swapping device 3. The command drives the battery swapping device 3 to complete a series of battery swapping operations, including grabbing the depleted battery, transferring it, and installing the fully charged battery, in an orderly manner between the vehicle to be processed and the battery compartment 2, according to a preset process. If the comparison result shows that the vehicle information does not match the preset list, it may be due to the vehicle not being registered, the model not being compatible, or the battery specifications not being suitable. In this case, the control module determines that the vehicle does not meet the conditions for battery swapping, and immediately generates a prompt signal that battery swapping is not allowed. The system then broadcasts a voice prompt to the driver through the speaker of the human-machine interaction system, clearly informing them of the result that battery swapping is not possible. This avoids battery swapping failures or safety risks caused by mismatched vehicle information, and ensures the accuracy and safety of the battery swapping process.

[0033] Optionally, such as Figure 1 As shown, the system also includes a 3D vision module 5, which is positioned above the battery swapping channel 4. The 3D vision module 5 is used to acquire the location of the vehicle-side battery on the vehicle to be processed and send the vehicle-side battery location to the control module. Controlling the battery swapping device 3 to replace the battery between the vehicle to be processed and the battery compartment 2 includes: Based on the received vehicle-side battery location, determine whether the location of the vehicle to be processed meets the battery swapping requirements; If so, the battery swapping device 3 is controlled to swap batteries between the vehicle to be processed and the battery compartment 2; If not, a re-parking prompt will be generated.

[0034] In this optional embodiment, the system further includes a 3D vision module 5, which is precisely deployed above the battery swapping channel 4. This module utilizes three-dimensional scanning technology to acquire the real-time location information of the vehicle-side battery on the vehicle to be processed. Through high-definition visual imaging and spatial coordinate positioning algorithms, it accurately captures the three-dimensional coordinates, angles, and surrounding environmental data of the battery mounting position, and transmits this precise vehicle-side battery location information to the control module in real time, providing core positioning basis for the operation of the battery swapping equipment 3. After receiving the vehicle-side battery location data from the 3D vision module 5, the control module compares and analyzes it with preset standard battery swapping location parameters, focusing on determining whether the actual parking position of the vehicle to be processed meets the operational requirements of the battery swapping equipment 3, including the alignment accuracy between the battery mounting position and the capture range of the battery swapping equipment 3. The control module measures factors such as the vehicle's position, levelness, and distance from the vehicle to the battery, ensuring these are within acceptable error ranges. If the vehicle's position meets the battery swapping requirements, the control module immediately issues precise operating instructions to the battery swapping device 3. This guides the device to plan the optimal operating path based on the vehicle's battery location information, efficiently completing operations such as removing and transferring depleted batteries and installing fully charged batteries. If the vehicle's position does not meet the swapping requirements, the control module immediately generates a re-parking prompt signal and broadcasts clear voice guidance to the driver through the speaker of the human-machine interface system. This informs the driver of the vehicle's parking position deviation and guides the driver to adjust the vehicle's position until the swapping conditions are met. This ensures that the battery swapping device 3 can accurately connect to the battery installation position, preventing swapping failures or equipment damage due to positional deviations and guaranteeing a smooth and safe swapping process.

[0035] Optionally, such as Figure 1 As shown, the battery compartment 2 includes a buffer position 21 and a mounting module 22. The buffer position 21 is located at one end of the battery compartment 2 near the battery swapping channel 4. Multiple mounting modules 22 are sequentially arranged within the battery compartment 2 along a first direction away from the battery swapping channel 4. Controlling the battery swapping device 3 to replace the battery between the vehicle to be processed and the battery compartment 2 includes: Based on the location of the vehicle-side battery, the battery swapping device 3 is controlled to grab the depleted battery from the vehicle to be processed and place it in the buffer position 21, and the fully charged battery from the rack module 22 is grabbed and placed in the vehicle-side battery position.

[0036] In this optional embodiment, the system further includes a buffer position 21 for temporary transfer batteries and a racking module 22 that performs battery storage and charging functions. The buffer position 21 is cleverly located at one end of the battery compartment 2 near the battery swapping channel 4, which enables rapid turnover of depleted and fully charged batteries, reducing the movement path and operation time of the battery swapping equipment 3. Multiple racking modules 22 are arranged sequentially in the battery compartment 2 along a first direction away from the battery swapping channel 4. Each racking module 22 integrates a battery storage frame and a modular charger, which can simultaneously complete the safe storage and efficient charging of batteries, and can provide real-time feedback on the battery's position status and charging progress through sensors. During battery replacement, the control module first sends a precise grabbing command to the battery swapping device 3 based on the accurate vehicle-side battery location data transmitted by the 3D vision module 5. This drives the battery swapping device 3 to move to the battery installation position of the vehicle to be processed. The device stably grabs the depleted battery from the vehicle through a hard-connected transmission structure and transfers it to the nearest buffer position 21 for temporary storage according to the preset optimal path. Subsequently, the control module combines the battery status information fed back by each racking module 22 to select fully charged batteries that are compatible with the vehicle. It then locks the position of the corresponding racking module 22 and sends a power-taking and installation command to the battery swapping device 3. This guides the battery swapping device 3 to accurately grab the fully charged battery from the designated racking module 22. After adjusting the alignment according to the vehicle-side battery position, the fully charged battery is smoothly installed in the battery installation position of the vehicle to be processed. The entire process, through the transfer connection of the buffer position 21 and the orderly arrangement of the racking modules 22, greatly improves the continuity and efficiency of battery replacement, ensuring a fast and smooth battery swapping process.

[0037] Furthermore, such as Figure 3 As shown, A is a 5+1 single-channel station type, meaning that the battery compartment 2 is divided into areas according to the modular principle of "independent function and collaborative operation". It includes 5 rack-mounting modules 22 and 1 buffer position 21. The buffer position 21 serves as an independent transfer module, and because it needs to quickly receive depleted batteries picked up by the battery swapping robot from the battery swapping channel 4, it is located at one end of the battery compartment 2 near the battery swapping channel 4. This buffer position 21 adopts a standardized size design, only serving the function of temporary battery storage, and does not integrate charging components, thus functionally decoupled from the rack-mounting modules 22. The rack-mounting modules 22, on the other hand, integrate "battery storage + modular charging". The composite functional module, each rack-mounted module 22, includes an independent battery storage frame (with guidance, limit and presence sensors) and a charger consisting of 8 40kW modules connected in parallel (supporting interlocking between battery charging in the station and vehicle charging outside the station). To meet the 24-hour battery swapping needs of 30 vehicles (120 times / 24h), the 5 rack-mounted modules 22 are arranged sequentially along the first direction away from the battery swapping channel 4 (such as the horizontal extension direction from the battery swapping channel 4 towards the inside of the battery compartment 2). Each rack-mounted module 22 interfaces with the station control system through a standardized interface and can independently realize battery presence detection, automatic charging and fault alarm.

[0038] The single-channel station type can be flexibly expanded according to actual battery swapping needs, such as... Figure 3 As shown, in addition to the basic 5+1 single-channel station type A (5 charging bays + 1 fixed buffer bay), various single-channel station types can be extended, such as 7+1 single-channel station type B, 9+1 single-channel station type C, and 11+1 single-channel station type D. Taking the expansion to the 9+1 single-channel station type as an example, this station type can meet the 24-hour battery swapping needs of 50 heavy trucks (up to 216 battery swaps per day). The expansion process only requires adding 4 rack-mounted modules 22 with completely identical specifications along the first direction away from the battery swapping channel (i.e., the horizontal extension direction inside the battery compartment). There is no need to adjust the position and structure of the buffer position 21 (the buffer position 21 is always fixed at the end of the battery compartment near the battery swapping channel to maintain the stability of the depleted battery transfer function), nor is it necessary to reconstruct the overall framework of the battery compartment 2 (relying on the control room box as a fixed architectural benchmark, only adding modules through standardized interfaces). This expansion approach fully demonstrates the core advantages of modular design: on the one hand, by clearly defining functional partitions (the cache is responsible for relaying, and the rack-mounted module is responsible for battery storage and charging), the functions of each module are decoupled, ensuring efficient connection of "depleted battery relay - fully charged battery storage - battery charging" in the battery swapping process; on the other hand, by standardizing module specifications and fixing architectural benchmarks, it not only reduces the customized development cost of expansion (directly reusing mature rack-mounted modules), but also shortens the station deployment cycle. At the same time, the independent fault response mechanism of each module (the failure of a single rack-mounted module does not affect the operation of other modules) can effectively avoid the interference of local problems on the overall battery swapping efficiency of the station, further adapting to the diverse needs of customers and scenarios.

[0039] Optionally, such as Figure 1 As shown, the step of controlling the battery swapping device 3 to grab the depleted battery from the vehicle to be processed and place it into the buffer position 21 according to the battery position of the vehicle includes: Send a battery unlock command to the vehicle to be processed; Once the vehicle to be processed is successfully unlocked, the battery swapping robot controlling the battery swapping device 3 grabs the depleted battery from the vehicle-side battery location and places it in the buffer position 21.

[0040] In this optional embodiment, after the control module confirms the location of the vehicle-side battery and that the vehicle meets the battery swapping location requirements through the 3D vision module 5, it first sends a battery unlocking command to the onboard battery swapping controller of the vehicle to be processed. This command communicates with the vehicle's vehicle controller via the internal network of the battery swapping station (such as WIFI). Through real-time interaction with the Vehicle Control Unit (VCU), the system clearly informs the vehicle to initiate the unlocking procedure for the battery mounting position. Once the control module receives a successful unlocking signal from the vehicle (confirming that the battery and the vehicle body's fixing structure have been completely released), it immediately issues a grabbing and transfer command to the battery swapping robot of the battery swapping device 3, based on the previously acquired precise vehicle-side battery position data. This command guides the battery swapping robot to move along a preset optimal path directly above the vehicle's battery mounting position. Through the precise positioning and stable clamping function of the rigid connection transmission structure, the robot smoothly grabs the depleted battery from the vehicle-side battery position, avoiding battery shaking or bumping during the grabbing process. Subsequently, the battery swapping robot precisely moves to the top of the buffer position 21 according to the preset trajectory, and smoothly places the depleted battery in the buffer position 21, completing the transfer and storage of the depleted battery from the vehicle to the buffer position 21. This reserves operating space for the subsequent installation of a fully charged battery. The entire process relies on closed-loop control of command interaction and precise actions of the equipment to ensure the safe and efficient removal and transfer of the depleted battery.

[0041] Optionally, such as Figure 1 As shown, the step of grabbing the fully charged battery of the loader module 22 to the vehicle-end battery position includes: Obtain the battery position at the end of the fully charged battery compartment; The fully charged battery is retrieved from the warehouse battery location to the vehicle battery location, and a battery locking command is sent to the vehicle to be processed. Once the vehicle to be processed is successfully locked, a battery swap completion notification will be generated.

[0042] In this optional embodiment, firstly, based on the feedback data from the sensors built into each racking module 22, the position of the fully charged battery in the compartment corresponding to the fully charged battery that is compatible with the vehicle to be processed is accurately obtained (including key information such as the three-dimensional coordinates and placement angle of the battery in the racking module 22); then, the control module, combined with the previously received vehicle-side battery position data, issues power-taking and alignment installation instructions to the battery-swapping robot of the battery-swapping device 3, guiding the battery-swapping robot to move along the optimal path to the battery position in the compartment of the target racking module 22, stably grabbing the fully charged battery through a hard-connected transmission structure, and then accurately transferring it to the vehicle-side battery position of the vehicle to be processed according to a preset trajectory, completing the connection between the fully charged battery and the vehicle battery. The battery installation position is precisely aligned and placed stably. After installation, the control module immediately sends a battery locking command to the vehicle's VCU. The command is transmitted via the vehicle-to-station communication link and drives the vehicle to initiate the locking procedure of the battery fixing structure. After the control module receives a successful locking signal from the vehicle (confirming that the battery is firmly fixed to the vehicle body), it determines that the full-charge battery installation process is closed. It then generates a battery swap completion prompt signal and broadcasts a voice prompt to the driver through the speaker of the human-machine interaction system, informing the driver that the battery swap operation has been safely completed and guiding the driver to drive away from the battery swap station. The entire process ensures that the grabbing, transportation, installation, and locking of the full-charge battery are precise and efficient, guaranteeing the safety and reliability of the battery swap results.

[0043] Optionally, such as Figure 1 and Figure 2 As shown, the gantry module 22 includes a battery storage unit 221, a charging unit 222, and a dual-channel charging gun 223. The battery storage unit 221 is used to store the battery, the charging unit 222 is used to charge the battery in the battery storage unit 221, and the dual-channel charging gun 223 is used to charge vehicles outside the station.

[0044] In this optional embodiment, the loader module 22, as a core component of the heavy-duty truck battery swapping system, integrates battery storage, in-station charging, and off-site energy replenishment functions. Its structural design and functional configuration are highly adaptable to diverse energy replenishment needs. Specifically, it includes three core parts: a battery storage unit 221, a charging unit 222, and a dual-channel charging gun 223. The battery storage unit 221 is equipped with a dedicated storage frame, guiding and limiting devices, and an on-site sensor, which can provide a safe and stable storage space for depleted and fully charged batteries. At the same time, the sensor monitors the battery's on-site status in real time to ensure the standardization and traceability of battery storage. The charging unit 222 adopts a modular design, consisting of multiple power modules connected in parallel, and has intelligent functions such as automatic charging, power metering, and fault alarm. Based on the battery status and health parameters of the batteries in the battery storage unit 221, the system can automatically match charging strategies to provide efficient and safe charging services for the stored batteries, ensuring that the batteries quickly return to full charge. The dual-channel charging guns 223, as extended energy replenishment interfaces, break through the limitation of the battery swapping station only serving vehicles within the station. They are specifically designed to provide flexible energy replenishment for vehicles with charging needs outside the station, supporting multiple charging modes such as single-gun charging of one vehicle, dual-gun charging of one vehicle simultaneously, or dual-gun charging of two vehicles separately. Furthermore, they are interlocked with the battery charging function within the station to avoid circuit conflicts. This not only improves the utilization rate of the carrier module 22 but also expands the service scenarios of the battery swapping station, allowing it to meet both the core needs of heavy-duty truck battery swapping and temporary charging needs, thus enhancing the system's practicality and flexibility. Optionally, the system also includes a fire protection subsystem, which includes fire detectors, manual fire alarm buttons, fire audible and visual alarm buttons, and a fire central controller. The fire detectors and manual fire alarm buttons are respectively installed in preset locations in the control room and the battery compartment. The fire central controller is installed in the control room and is communicatively connected to the fire detectors and the manual fire alarm buttons.

[0045] In this optional embodiment, the system also includes a fire protection subsystem that provides comprehensive protection for battery swapping safety. Its core consists of fire detectors, manual fire alarm buttons, fire alarm audible and visual alarms, and a centralized fire controller. These components, through scientific layout and coordinated operation, construct a complete fire protection system of "automatic monitoring - manual triggering - centralized control - audible and visual warning." The fire detectors and manual fire alarm buttons are precisely deployed in preset locations in key areas such as the control room and battery compartment. The fire detectors can detect early warning signals of fire, such as smoke concentration and temperature anomalies, in real time, achieving automatic early warning of fires. The manual fire alarm buttons are convenient for personnel to use. Upon discovering a fire, personnel can proactively trigger the alarm immediately, forming a dual guarantee of automatic monitoring and manual triggering. The fire control center, as the core control hub of the fire protection subsystem, is centrally located in the control room. It establishes connections with fire detectors and manual fire alarm buttons in various areas through a stable communication link. It can receive various alarm signals in real time and analyze and judge the signals. Once a fire is confirmed, it can immediately activate the fire alarm to emit a strong audible and visual warning signal, reminding on-site personnel to take timely evacuation. At the same time, it provides a control basis for subsequent activation of fire extinguishers and other fire-fighting equipment and precise handling of the fire, comprehensively protecting the safety of the battery swapping station, personnel, and vehicles.

[0046] Optionally, the system further includes a station interaction subsystem, which is used for: The indicator light color is displayed according to the channel status of the battery swapping channel and the preset status matching rule, wherein the status matching rule includes a one-to-one correspondence between the channel status and the indicator light color.

[0047] In this optional embodiment, the system further includes a station interaction subsystem that provides visual guidance for the battery swapping process and improves vehicle traffic efficiency. The core of this subsystem is a linked display function of channel status and indicator light colors, which can intuitively convey the real-time usage status of the battery swapping channel to vehicles waiting for swapping, ensuring the orderly scheduling of the battery swapping channel. Its working logic involves real-time collection of the current channel status of the battery swapping channel, including the channel operation status throughout the entire battery swapping process: idle and accessible, battery swapping in progress and prohibited, equipment malfunction and unusable, and vehicles needing to stop again. Simultaneously, the system has pre-set standardized status matching rules, which clearly define a one-to-one pairing of each channel status with the indicator light color. The system ensures that there are no overlaps or intersections between the data points. The station's interactive subsystem accurately matches the real-time channel status with preset status matching rules. Based on the matching results, it controls the indicator lights next to the battery swapping channel to display corresponding colors. For example, green indicates the channel is empty, red indicates battery swapping is in progress, yellow indicates equipment failure, and flashing yellow indicates the need to stop again. This highly recognizable color signal enables the visualization of the channel status, allowing drivers of vehicles waiting for battery swapping to quickly know the channel status without manual inquiry. This allows them to make timely decisions on whether to enter, wait, or leave, effectively reducing channel congestion and unnecessary vehicle waiting, and improving the turnover efficiency of the battery swapping channel and the level of intelligence in the battery swapping process.

[0048] Optionally, the station interaction subsystem is also used to provide system prompts via loudspeaker announcements.

[0049] In this optional embodiment, the station interaction subsystem also integrates an audio broadcasting function. Through speakers deployed around the battery swapping lane and outside the control room—locations easily accessible to drivers—various system prompts can be broadcast in real-time to drivers of vehicles awaiting processing, enabling voice-based guidance and information synchronization throughout the battery swapping process. The broadcasted system prompts cover key aspects of the entire battery swapping process, including legal entry after vehicle identity verification, prohibition of battery swapping for unauthorized vehicles, re-parking guidance when a vehicle's parking position deviates, safety warnings during battery swapping equipment operation, successful battery swapping notifications after battery locking, and alerts for equipment malfunctions and lane occupancy. The system provides alerts for abnormal situations, and the voice prompts are concise, clear, and highly recognizable, making it suitable for the acoustic environment of outdoor operations. This audio broadcast function works in conjunction with the indicator light color display function to create a dual interactive guidance system combining visual and auditory elements. This solves the recognition problems that may arise from visual guidance alone, such as obstructed vision or excessive distance. Furthermore, it allows drivers to obtain real-time operation instructions and status information for the battery swapping process without having to check the indicator lights while driving, further improving the effectiveness and convenience of battery swapping guidance, reducing operational delays caused by poor information transmission, and ensuring the efficiency of the battery swapping channel and the orderly progress of the battery swapping process.

[0050] Optionally, such as Figure 1As shown, the system also includes at least one first housing 7, a second housing 8, and a maintenance room 6. The battery compartment 2 includes a buffer position 21 and a carrier module 22. The maintenance room 6 is used to house the control room 1. One first housing 7 is used to house the buffer position 21, and the other first housings 7 are respectively housed in the carrier module 22. The second housing 8 is located above the battery swapping channel 4 between the maintenance room 6 and the first housing 7. The first housings 7, the second housings 8, and the maintenance room 6 are sequentially connected and interconnected. The first housing 7 with the buffer position 21 is located near the battery swapping channel 4. The battery swapping robot's battery swapping track is located in the channel formed by the first housing 7, the second housing 8, and the maintenance room 6.

[0051] In this optional embodiment, the battery compartment 2 consists of a buffer space 21 and a mounting module 22. The maintenance room 6 is specifically designed to house the control room 1 above it. One first housing 7 is configured to support the buffer space 21, while the remaining first housings 7 are respectively equipped with mounting modules 22, realizing a modular layout for battery storage and charging functions. The second housing 8 is mounted directly above the battery swapping channel 4 between the maintenance room 6 and the first housings 7. The first housings 7, the second housings 8, and the maintenance room 6 are sequentially connected in a reasonable order and are internally interconnected, forming a continuous operation and maintenance space. It is also clearly stated that the first housing 7 with the buffer space 21 is adjacent to the battery swapping channel 4. The battery swapping robot has a shorter path and higher efficiency when grabbing and storing batteries. The battery swapping robot's swapping track is laid inside the channel formed by the first box 7, the second box 8 and the maintenance room 6, which allows the battery swapping robot to move flexibly between the boxes and the maintenance room. It can efficiently complete the battery transfer and swapping operation between the buffer position 21, the carrier module 22 and the battery swapping channel 4. When maintenance and repair are required, it can move directly along the track to the maintenance room 6. Combined with the layout of the control room 1 in the maintenance room 6, it further improves the operational continuity, maintenance convenience and overall modular integration of the battery swapping system, and enhances the system's scalability and practicality.

[0052] While the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A heavy-duty truck battery swapping system, characterized in that, The system includes a control room (1), a battery compartment (2), and a battery swapping device (3). A battery swapping channel (4) is provided between the control room (1) and the battery compartment (2). The battery swapping device (3) is mounted above the control room (1) and the battery compartment (2). The control room (1) includes a control module, which is communicatively connected to both the battery compartment (2) and the battery swapping device (3). The control module is used for: Based on the status of the vehicle to be processed in the battery swapping channel (4), the battery swapping equipment (3) is controlled to swap batteries between the vehicle to be processed and the battery compartment (2).

2. The heavy-duty truck battery swapping system according to claim 1, characterized in that, The step of controlling the battery swapping equipment (3) to swap batteries between the vehicle to be processed and the battery compartment (2) based on the status of the vehicle in the battery swapping channel (4) includes: Obtain the vehicle information of the vehicle to be processed; If the vehicle information is the same as the preset battery information of the vehicle to be replaced, then control the battery swapping device (3) to replace the battery between the vehicle to be processed and the battery compartment (2); Otherwise, a message indicating that battery swapping is not allowed will be generated.

3. The heavy-duty truck battery swapping system according to claim 2, characterized in that, It also includes a 3D vision module (5), which is located above the battery swapping channel (4) and is used to obtain the position of the vehicle-end battery on the vehicle to be processed and send the position of the vehicle-end battery to the control module. The control of the battery swapping device (3) to swap batteries between the vehicle to be processed and the battery compartment (2) includes: Based on the received vehicle-side battery location, determine whether the location of the vehicle to be processed meets the battery swapping requirements; If so, the battery swapping device (3) is controlled to swap batteries between the vehicle to be processed and the battery compartment (2); If not, a re-parking prompt will be generated.

4. The heavy-duty truck battery swapping system according to claim 3, characterized in that, The battery compartment (2) includes a buffer position (21) and a carrier module (22). The buffer position (21) is located at one end of the battery compartment (2) near the battery swapping channel (4). A plurality of carrier modules (22) are sequentially arranged in the battery compartment (2) along a first direction away from the battery swapping channel (4). The control of the battery swapping device (3) to swap batteries between the vehicle to be processed and the battery compartment (2) includes: According to the vehicle-end battery position, the battery swapping device (3) is controlled to grab the depleted battery on the vehicle to be processed and place it in the buffer position (21), and the fully charged battery of the racking module (22) is grabbed and placed in the vehicle-end battery position.

5. The heavy-duty truck battery swapping system according to claim 4, characterized in that, The step of controlling the battery swapping device (3) to grab the depleted battery on the vehicle to be processed and place it in the buffer position (21) according to the battery position of the vehicle includes: Send a battery unlock command to the vehicle to be processed; When the vehicle to be processed is successfully unlocked, the battery swapping robot controlling the battery swapping equipment (3) grabs the depleted battery from the vehicle-end battery position and puts it into the buffer position (21).

6. The heavy-duty truck battery swapping system according to claim 4, characterized in that, The step of grabbing the fully charged battery of the loader module (22) and placing it at the vehicle-end battery position includes: Obtain the battery position at the end of the fully charged battery compartment; The fully charged battery is retrieved from the warehouse battery location to the vehicle battery location, and a battery locking command is sent to the vehicle to be processed. Once the vehicle to be processed is successfully locked, a battery swap completion notification will be generated.

7. The heavy-duty truck battery swapping system according to claim 4, characterized in that, The gantry module (22) includes a battery storage unit (221), a charging unit (222), and a dual-channel charging gun (223). The battery storage unit (221) is used to store the battery, the charging unit (222) is used to charge the battery in the battery storage unit (221), and the dual-channel charging gun (223) is used to charge vehicles outside the station.

8. The heavy-duty truck battery swapping system according to claim 1, characterized in that, It also includes a fire protection subsystem, which includes fire detectors, manual fire alarm buttons, fire sound and light alarm buttons and a fire central controller. The fire detectors and the manual fire alarm buttons are respectively set in preset positions in the control room (1) and the battery compartment (2). The fire central controller is set in the control room (1) and is communicatively connected to the fire detectors and the manual fire alarm buttons.

9. The heavy-duty truck battery swapping system according to claim 1, characterized in that, It also includes a station interaction subsystem, which is used for: The corresponding indicator light color is displayed according to the channel status of the battery swapping channel (4) and the preset status matching rule, wherein the status matching rule includes a one-to-one correspondence between the channel status and the indicator light color; And / or, through a loudspeaker announcement system.

10. The heavy-duty truck battery swapping system according to claim 1, characterized in that, It also includes at least one first housing (7), a second housing (8), and a maintenance room (6). The battery compartment (2) includes a buffer position (21) and a carrier module (22). The maintenance room (6) is used to house the control room (1). One first housing (7) is used to house the buffer position (21). The carrier module (22) is respectively housed in the other first housings (7). The second housing (8) is located above the battery swapping channel (4) between the maintenance room (6) and the first housing (7). Each of the first housings (7), the second housing (8), and the maintenance room (6) is connected in sequence and communicates with each other. The first housing (7) with the buffer position (21) is close to the battery swapping channel (4). The battery swapping track of the battery swapping robot is located in the channel formed by the first housing (7), the second housing (8), and the maintenance room (6).

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