Battery swapping station and battery swapping method thereof

Abstract

The application provides a battery replacement station and a battery replacement method thereof, comprising a battery replacement device, a charging area and a battery replacement area. The battery replacement device comprises a battery replacement robot, the battery replacement robot is provided with a telescopic arm assembly and a grabber, the free end of the telescopic arm assembly is provided with a leveling mechanism, the leveling mechanism comprises a swing rod and a driving piece, both ends of the swing rod are connected with a sling, the grabber is connected with the sling, and the driving piece and the swing rod are in transmission connection to drive the swing rod to rotate and adjust the inclination angle of the swing rod. The application considers that the telescopic arm hoisting battery box has large deflection and the battery box is prone to tilting, the posture of the grabber is adjusted in advance, the grabber is low inside and high outside, in the process of hoisting or lowering the battery box by the grabber, the battery box is not tilted or has small inclination angle, damage such as extrusion and collision of the connector on the bottom support is avoided, and the connection stability and service life of the connector are ensured.

Description

Technical Field

[0001] This disclosure relates to the field of battery swapping technology, and in particular to a battery swapping station and a battery swapping method thereof. Background Technology

[0002] With the automation and efficiency development of the mining transportation industry, mining trucks, as core transportation equipment, directly affect the overall operation progress due to their battery replenishment efficiency. Battery swapping stations, with their automated battery swapping capabilities, have become a key infrastructure for the rapid replenishment of mining truck battery boxes. Existing battery swapping stations typically include battery swapping equipment, a charging area, and a battery swapping area. The charging area and battery swapping area are located on opposite sides of the battery swapping equipment. The battery swapping robot in the equipment uses a telescopic arm assembly to drive the gripper to extend and retract in both directions, realizing the transfer of battery boxes between the charging area (where fully charged battery boxes are stored) and the battery swapping area (where battery boxes are replaced for mining trucks), thus completing the automated battery swapping operation for mining trucks.

[0003] The telescopic arm assembly is the core actuator of the battery swapping robot. Its free end is connected to the gripper via a sling, and the gripper holds or suspends the battery box to complete actions such as lifting, moving, and lowering. However, in actual heavy-duty battery swapping scenarios, when the telescopic arm assembly is in its extended state to lift the battery box, it is prone to deflection and deformation due to multiple factors, including the weight of the battery box itself, the deflection of the telescopic arm structure, manufacturing errors of components, and clearances in the mechanism. This can lead to the gripper and the battery box it carries tilting. The tilting of the battery box can cause a series of serious problems, becoming a core bottleneck restricting the stability and efficiency of battery swapping station operations. On the one hand, during the lifting, lowering, and docking with the base, the tilted battery box will cause damage to the connectors on the base, such as squeezing, bumping, and uneven wear, which will damage the structural integrity and connection stability of the connectors. This will not only significantly shorten the service life of the connectors and increase the cost of replacement and maintenance of parts, but may also cause safety hazards such as poor contact and power outages due to connector damage, affecting the normal operation of the battery swapping station. On the other hand, the tilting of the battery box will cause uneven stress on the slings and local overload of the grippers, accelerating the wear of components such as slings and grippers, increasing the risk of component failure, and may even cause major safety accidents such as battery box falling, threatening the safety of battery swapping station operations.

[0004] To address these issues, existing technologies often employ methods such as adding shims at the sling connections to adjust length or increasing the structural rigidity of the telescopic boom to reduce deflection. However, adding shims only achieves static leveling and cannot accommodate deflection changes during the dynamic extension of the telescopic boom. Furthermore, it has inherent limitations for bidirectional telescopic operation scenarios at battery swapping stations, where leveling one side can exacerbate tilting on the other. Increasing structural rigidity has a negligible effect on improving deflection deformation and significantly increases equipment manufacturing costs and weight, hindering the flexible extension and retraction of the telescopic boom and resulting in extremely poor adaptability. Summary of the Invention

[0005] To address one of the aforementioned technical problems, this invention provides a battery swapping station and a battery swapping method thereof.

[0006] The present invention adopts the following technical solution: In a first aspect, embodiments of this application provide a battery swapping station, comprising: A battery swapping device, comprising a battery swapping robot, the battery swapping robot having a telescopic arm assembly and a gripper, the free end of the telescopic arm assembly being provided with a leveling mechanism, the leveling mechanism comprising a swing arm and a drive component, the two ends of the swing arm being connected to slings, the gripper being connected to the slings, the drive component being kinetically connected to the swing arm to drive the swing arm to rotate and adjust the tilt angle of the swing arm; The charging area and the battery swapping area are located on both sides of the battery swapping equipment. The telescopic arm assembly can extend and retract in both directions, and can drive the gripper to move between the charging area and the battery swapping area to transfer the battery box between the battery swapping area and the charging area. Specifically, before the telescopic arm assembly extends to lift or unload the battery box, the drive unit drives the swing arm to rotate so that the end of the swing arm closer to the battery swapping device is lower than the end farther away from the battery swapping device.

[0007] Optionally, the telescopic boom assembly includes a telescopic frame; The middle part of the swing arm is rotatably connected to the telescopic frame; The driving component is connected to the swing arm and the telescopic frame respectively. The driving component can extend and retract to drive the swing arm to rotate.

[0008] Optionally, the drive member has a limit elongation state and a limit retraction state; Before the telescopic arm assembly extends to lift or unload the battery box, the drive unit moves to its maximum extension or maximum retraction state, so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device.

[0009] Optionally, the drive member also has a neutral position, in which the swing arm is parallel to the telescopic frame when the drive member is moved to the neutral position.

[0010] Optionally, the battery swapping robot has a main frame and a lifting frame; The lifting frame is vertically and flexibly connected to the main frame; The telescopic arm assembly is connected to the lifting frame at one end away from the leveling mechanism.

[0011] Optionally, the telescopic arm assembly includes multiple support arms, at least some of the support arms are provided with sliding grooves, the sliding grooves extend along the telescopic direction of the support arm, at least some of the support arms are provided with multiple rollers, each roller is arranged sequentially along the telescopic direction of the support arm, at least some of the support arms are provided with multiple support bodies, the center of each roller on the support arm is located on a straight line of the center, the support bodies on the support arm are located on one or both sides of the straight line of the center along the thickness direction of the support arm, the thickness direction is perpendicular to the telescopic direction of the support arm, the support arms are arranged sequentially, one of the rollers of two adjacent support arms can be supported by the sliding groove of the other, and the leveling mechanism is provided on the support arm at the tail end; During the extension of the telescopic arm assembly, some rollers of the next-level support arm extend out of the groove of the previous-level support arm before the support body. During the retraction of the telescopic arm assembly, the support body of the next-level support arm slides into the groove of the previous-level support arm before some of the rollers.

[0012] Secondly, embodiments of this application also provide a battery swapping method for a battery swapping station, including: Control the telescopic arm assembly to extend and retract, driving the gripper to move between the charging area and the battery swapping area, transferring the depleted battery pack from the vehicle to the charging area, and transferring the fully charged battery pack from the charging area to the vehicle. During the process of transferring the battery box using the telescopic arm assembly, the tilt angle of the swing arm is adjusted by the leveling mechanism to level the battery box.

[0013] Optionally, during the process of transferring the battery box using the telescopic arm assembly, adjusting the tilt angle of the swing arm via a leveling mechanism to level the battery box includes: Before the telescopic boom assembly extends to lift the battery pack, the leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm closer to the battery swapping equipment is lower than the end farther away from the battery swapping equipment. Before the telescopic arm assembly extends to unload the battery box, the leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm closer to the battery swapping device is lower than the end farther away from the battery swapping device.

[0014] Optionally, the battery swapping methods at the battery swapping station include: Step S1: The telescopic arm assembly extends so that the gripper is located in the battery swapping area. The gripper grabs the battery box on the vehicle. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm near the battery swapping equipment is lower than the end away from the battery swapping equipment. The battery swapping robot lifts the telescopic arm assembly and hoists the battery box on the vehicle. Step S2: The telescopic arm assembly drives the battery box to extend to one side of the charging area. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device. The battery swapping robot moves the telescopic arm assembly down to unload the battery box into the charging area. Step S3: The telescopic arm assembly moves the gripper to the top of the fully charged battery box in the charging area and grabs the fully charged battery pack. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device. The battery swapping robot lifts the telescopic arm assembly and hoists the fully charged battery box. Step S4: The telescopic arm assembly drives the gripper to extend to one side of the battery swapping area. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm closer to the battery swapping equipment is lower than the end farther away from the battery swapping equipment. The battery swapping robot moves the telescopic arm assembly down to unload the fully charged battery box onto the vehicle.

[0015] Optionally, the drive member has a limit elongation state, a limit retraction state, and a neutral state; In steps S1 and S4, the driving member moves to its maximum extension state or maximum retraction state, so that the end of the swing arm near the power swapping device is lower than the end away from the power swapping device. In steps S2 and S3, the drive member moves to its limit retraction state or limit extension state, so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device. In step S2, when the telescopic arm assembly drives the battery box to move past the battery swapping equipment, the driving component moves to the limit retraction state or the limit extension state. Between steps S2 and S3, the drive member is moved to the neutral position, causing the swing arm to rotate to be parallel to the extension direction of the telescopic arm assembly.

[0016] By adopting the above technical solution, this disclosure has the following beneficial effects: This application takes into account the large deflection of the battery box when the telescopic boom is used for lifting, which may cause the battery box to tilt. The gripper posture is adjusted in advance so that the inside of the gripper is lower than the outside. During the process of lifting or lowering the battery box, the battery box does not tilt or tilts at a small angle, avoiding damage such as squeezing or bumping to the connector on the base, and ensuring the connection stability and service life of the connector.

[0017] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0018] The accompanying drawings, as part of this disclosure, are provided to further illustrate the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention but do not constitute an undue limitation thereof. Obviously, the drawings described below are merely some embodiments, and those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings: Figure 1 This illustration shows a three-dimensional structural diagram of the battery swapping station provided in an embodiment of this application; Figure 2 This diagram shows a partial three-dimensional structural schematic of the battery swapping station provided in an embodiment of this application; Figure 3 This illustration shows another partial structural diagram of the battery swapping station provided in an embodiment of this application; Figure 4 This illustration shows a schematic diagram of the structure of the battery swapping robot in the battery swapping station provided in an embodiment of this application; Figure 5 This illustration shows the cooperative structure of the end support arm, leveling mechanism, and gripper in the battery swapping robot of the battery swapping station provided in the embodiments of this application; Figure 6 Show Figure 5 Enlarged view of section A in the middle; Figure 7 This illustration shows a structural diagram of another battery swapping robot in a battery swapping station provided in an embodiment of this application; Figure 8 Show Figure 7 Enlarged view of section B; Figure 9 Show Figure 7 Enlarged view of section C; Figure 10 This illustration shows another perspective view of the battery swapping robot in the battery swapping station provided in the embodiments of this application; Figure 11 An exploded view of the telescopic arm assembly of the battery swapping robot in the battery swapping station provided in the embodiments of this application is shown.

[0019] In the diagram: 100, Battery swapping equipment; 1, Battery swapping robot; 11, Main body; 111, Main frame; 112, Lifting frame; 12, Telescopic arm assembly; 121, Support arm; 1211, Slide groove; 12111, Second guide ramp; 1212, Limiting component; 1213, Hinge seat; 1214, Roller; 1215a, Lower support body; 1215b, Upper support body; 1215b1, Inner upper support body; 1215b2, Outer upper support body; 12151, Support... Support component; 121511, Support surface; 121512, First guide slope; 12152, Support; 121521, Main board; 121522, End; 122, Leveling mechanism; 1221, Swing rod; 12211, Hinge groove; 12212, Notch; 12213, Sling seat; 1222, Drive component; 123, Sling; 13, Grab; 2, Track; 200, Charging area; 300, Battery swapping area; 400, Vehicle; 500, Battery box.

[0020] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0022] In the description of this invention, it should be noted that the terms "upper", "lower", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] Example 1 like Figures 1 to 11 As shown in the figure, this application embodiment provides a battery swapping station, including: a battery swapping device 100, a charging area 200 and a battery swapping area 300. The battery swapping device 100 includes a battery swapping robot 1. The battery swapping robot 1 has a telescopic arm assembly 12 and a gripper 13. The free end of the telescopic arm assembly 12 is provided with a leveling mechanism 122. The leveling mechanism 122 includes a swing arm 1221 and a drive member 1222. The two ends of the swing arm 1221 are connected to slings 123. The gripper 13 is connected to the slings 123. The drive member 1222 and the swing arm 1221 are connected in a transmission connection to drive the swing arm 1221 to rotate and adjust the tilt angle of the swing arm 1221. The charging area 200 and the battery swapping area 300 are located on opposite sides of the battery swapping device 100. The telescopic arm assembly 12 is bidirectionally extendable and retractable, enabling the gripper 13 to move between the charging area 200 and the battery swapping area 300 for transferring the battery box 500 between them. Before the telescopic arm assembly 12 extends to lift or unload the battery box 500, the drive member 1222 drives the swing arm 1221 to rotate, causing the end of the swing arm 1221 closer to the battery swapping device 100 to be lower than the end farther from the device 100.

[0025] This application specifically addresses the core issue of excessive deflection when lifting the battery box 500 with a telescopic boom. Before lifting or lowering the battery box 500, the gripper 13 is pre-adjusted to a preset state with an inner bottom and an outer elevation. This posture precisely counteracts the deflection deformation of the telescopic boom assembly 12 caused by heavy loads. This ensures that the battery box 500 remains basically level or only slightly tilted during the critical process of lifting and lowering the battery box 500, fundamentally solving the industry problem of battery box 500 tilting in existing technologies. It also provides comprehensive protection for the base connector, improving the stability and service life of the components. By pre-adjusting the posture, the tilt of the battery box 500 is avoided, completely eliminating the damage to the connectors on the base (both the charging area 200 and the vehicle are equipped with bases) caused by the tilted battery box 500 during lifting, lowering and docking. This effectively ensures the structural integrity and connection stability of the connectors, greatly extends the service life of the connectors, reduces the frequency of replacement and maintenance of parts, reduces the operating cost of the battery swapping station, and avoids safety hazards such as poor power supply contact caused by connector damage.

[0026] The pre-adjusted posture of the gripper 13, with its inner bottom and outer height, ensures that the battery box 500 remains stably attached to the gripper 13 and sling 123 during lifting and lowering. This avoids problems such as uneven stress on the sling 123 and localized overload of the gripper 13 caused by tilting. It also reduces the hard impact between the battery box 500 and the base and connector, resulting in more stable stress on the components of the battery swapping equipment 100, including the telescopic arm assembly 12, sling 123, and gripper 13. This reduces wear and tear on individual components and the risk of failure, extending the overall lifespan of the battery swapping robot 1 and adapting to the heavy-duty, high-frequency operation requirements of mining truck battery swapping stations. The pre-tilted swing arm 1221 eliminates the need for tilt corrections during lifting and lowering, reducing the load and simplifying adjustments. The pre-adjustment of the gripper 13's attitude can be automatically completed by the control system of the battery swapping robot 1 without human intervention. This, combined with the automated leveling mechanism 122, achieves full automation of the battery swapping operation, from attitude pre-adjustment and lifting / transfer to lowering and docking. This aligns with the trend of unmanned and intelligent battery swapping in mining operations, while reducing errors and safety risks associated with manual operation. The attitude pre-adjustment design in this application is an improvement on the existing battery swapping robot 1. It requires no major modifications to the overall layout of the battery swapping station or the core structure of the battery swapping equipment 100. It can seamlessly adapt to the upgrade and renovation of existing mining truck battery swapping stations and can also be directly applied to the construction of new battery swapping stations. It has low modification costs, strong practicality, and broad application value.

[0027] In some possible implementations, the telescopic arm assembly 12 includes a telescopic frame, a swing arm 1221 rotatably connected to the telescopic frame at its center, and a drive member 1222 connected to the swing arm 1221 and the telescopic frame respectively. The drive member 1222 is telescopic to drive the swing arm 1221 to rotate.

[0028] The drive component 1222 connects to the swing arm 1221 and the telescopic frame, respectively, and has a telescopic movement function. Through its own telescopic movement, it generates power transmission, precisely driving the swing arm 1221 to rotate around the fulcrum on the telescopic frame, adjusting the relative tilt angle between the swing arm 1221 and the telescopic frame, and providing reliable power for attitude adjustment. The position of the drive component 1222 can be flexibly adjusted, located at one or both ends of the swing arm 1221 along its length. When located at both ends, the two drive components 1222 move in opposite directions (one extending and one retracting), improving leveling accuracy and stability through reverse linkage. The drive component 1222 can be a hydraulic cylinder, pneumatic cylinder, electric push bar, etc., to adapt to different heavy-duty scenario requirements.

[0029] In some possible implementations, the drive member 1222 has a maximum extension state and a maximum retraction state. Before the telescopic arm assembly 12 extends to lift or unload the battery box 500, the drive member 1222 moves to the maximum extension state or the maximum retraction state, such that the end of the swing arm 1221 near the battery swapping device 100 is lower than the end away from the battery swapping device 100.

[0030] In this application, the drive component 1222 does not require a complex stepless adjustment structure. It is preferred to use a hydraulic cylinder or a pneumatic cylinder, which greatly simplifies the overall structural design. Specifically, the adjustment parameters required for leveling the battery box 500 (such as the rotation angle of the swing arm 1221) can be determined in advance based on the weight of the battery box 500 and the structure of the telescopic arm assembly 12. Then, a hydraulic cylinder or pneumatic cylinder with a corresponding stroke can be designed based on the adjustment parameters, so that the maximum extension stroke or maximum retraction stroke of the hydraulic cylinder or pneumatic cylinder accurately matches the parameters of leveling the battery box 500. Preset posture adjustment can be achieved without additional precise control, which is suitable for heavy-duty battery swapping needs.

[0031] The drive component 1222 in this application abandons the complex stepless adjustment structure and uses conventional components such as hydraulic cylinders and pneumatic cylinders. The stroke is designed with preset parameters, significantly simplifying the structure and reducing manufacturing costs and the probability of failure. At the same time, the standardized hydraulic cylinders and pneumatic cylinders facilitate procurement and maintenance, further reducing the long-term operating costs of the battery swapping station. This application can pre-determine the leveling parameters based on the 500kg weight of the battery box and the telescopic arm structure, and design the maximum stroke of the drive component 1222 (such as a hydraulic cylinder). During operation, the attitude pre-adjustment can be achieved simply by the drive component 1222 reaching its limit state, eliminating the need for real-time precise control, simplifying the control program, improving attitude adjustment efficiency, and adapting to the rapid battery swapping needs of the battery swapping station.

[0032] In some possible implementations, the drive component 1222 also has a neutral position. When the drive component 1222 moves to the neutral position, the swing arm 1221 is parallel to the telescopic frame (e.g., parallel to the telescopic direction of the telescopic frame). Optionally, in the neutral position, the extension dimension of the drive component 1222 is smaller than the extension dimension in the ultimate extension state. When the gripper 13 is unloaded, the drive component 1222 can move to the neutral position, at which time the gripper 13 is in a horizontal state, facilitating the successful gripping of the battery box 500. When the drive component 1222 is a hydraulic cylinder, a magnetic field telescopic displacement sensor can be added to the hydraulic cylinder to read the stroke, enabling the hydraulic cylinder to accurately position itself to the neutral position. Adding a magnetic field telescopic displacement sensor to the hydraulic cylinder can accurately read the stroke and achieve accurate positioning in the neutral position, avoiding deviation in the horizontality of the gripper 13 due to neutral position offset, further ensuring the accuracy of unloaded gripping. At the same time, the sensor has accurate detection, strong anti-interference ability, and is suitable for harsh mining operating environments.

[0033] The drive component 1222 has three states: extreme extension, extreme retraction, and neutral position. These states are suitable for heavy-load and no-load scenarios, respectively. It can meet the posture requirements of the entire battery swapping process without replacing any parts. Combined with the simple structure of the hydraulic / pneumatic cylinder, it balances operational stability and process convenience, adapting to the continuous operation rhythm of the battery swapping station. In the neutral position, the drive component 1222 ensures that the swing arm 1221 is parallel to the telescopic frame and the gripper 13 remains horizontal. When no load is applied, it can quickly align with the battery box 500 without additional adjustments, avoiding gripping deviations caused by the tilt of the gripper 13 and collisions with the battery box 500. This significantly improves the gripping success rate and optimizes the continuity of the battery swapping operation process.

[0034] In some possible implementations, the battery swapping robot 1 has a main frame 111 and a lifting frame 112, the lifting frame 112 being vertically and vertically connected to the main frame 111, and the end of the telescopic arm assembly 12 facing away from the leveling mechanism 122 being connected to the lifting frame 112. The battery swapping device 100 may also include a track 2, with a charging area 200 and a battery swapping area 300 located on both sides of the track 2 along its width. The main frame 111 can translate along the track 2, while the lifting frame 112 can drive the telescopic arm assembly 12 to move vertically, performing the action of lifting or unloading the battery box 500.

[0035] In some possible implementations, the telescopic frame of the telescopic arm assembly 12 includes multiple support arms 121. At least a portion of the support arms 121 are provided with sliding grooves 1211, which extend along the telescopic direction of the support arms 121. At least a portion of the support arms 121 are provided with multiple rollers 1214, which are arranged sequentially along the telescopic direction of the support arms 121. At least a portion of the support arms 121 are provided with several support bodies. The centers of the rollers 1214 on the support arms 121 are located on a straight line with the center. The support bodies on the support arms 121 are located on one or both sides of the straight line with the center along the thickness direction of the support arm 121, which is perpendicular to the telescopic direction of the support arms 121. The support arms 121 are arranged sequentially, and the rollers 1214 of one of two adjacent support arms 121 can be supported by the sliding groove 1211 of the other. The leveling mechanism 122 is provided at the tail end of the support arm 121. During the extension of the telescopic arm assembly 12, a portion of the rollers 1214 of the next-level support arm 121 extends out of the groove 1211 of the previous-level support arm 121 before the support body. During the retraction of the telescopic arm assembly 12, the support body of the next-level support arm 121 slides into the groove 1211 of the previous-level support arm 121 before a portion of the rollers 1214.

[0036] This embodiment also provides a battery swapping method for the above-mentioned battery swapping station, including: Control the telescopic arm assembly 12 to extend and retract, drive the gripper 13 to move between the charging area 200 and the battery swapping area 300, transfer the depleted battery box 500 on the vehicle 400 to the charging area 200, and transfer the fully charged battery box 500 in the charging area 200 to the vehicle 400. During the process of transferring the battery box 500 by the telescopic arm assembly 12, the tilt angle of the swing arm 1221 is adjusted by the leveling mechanism 122 to level the battery box 500.

[0037] In some possible implementations, the process of adjusting the tilt angle of the swing arm 1221 via the leveling mechanism 122 to level the battery box 500 during the transfer of the battery box 500 by the telescopic arm assembly 12 includes: Before the telescopic boom assembly 12 extends to lift the battery pack, the leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 closer to the battery swapping device 100 is lower than the end farther away from the battery swapping device 100; Before the telescopic arm assembly 12 extends to unload the battery box 500, the leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 closer to the battery swapping device 100 is lower than the end farther away from the battery swapping device 100.

[0038] Before lifting and unloading the battery box 500, the telescopic boom assembly 12 has opposite motion states of the same drive component 1222, one being the extreme extension state and the other being the extreme retraction state.

[0039] Before the telescopic boom assembly 12 extends to lift the battery box 500, and before the telescopic boom assembly 12 extends to unload the battery box 500, the leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 closer to the battery swapping device 100 is lower than the end farther away from the battery swapping device 100. This preset posture counteracts the influence of the telescopic boom's heavy-load deflection in advance, ensuring that the battery box 500 remains stable and does not tilt during lifting and unloading. When two drive components 1222 are connected to both ends of the same swing arm 1221, the states of the two drive components 1222 are also opposite. When one is in the extreme extension state and the other is in the extreme retraction state, the two drive components 1222 can also be in the neutral position at the same time.

[0040] The battery swapping method generally includes the following steps: Operational Preparation: The battery swapping robot 1 moves to the target vehicle 400 in the battery swapping area 300 and controls the drive component 1222 to move to the neutral position. At this time, the extension dimension of the drive component 1222 is less than the limit extension and limit retraction state, the swing arm 1221 is parallel to the telescopic frame, and the gripper 13 remains horizontal, preparing for precise gripping of the depleted battery box 500. If the drive component 1222 is a hydraulic cylinder, the stroke is read by the magnetic field telescopic displacement sensor added to it to ensure that the drive component 1222 is accurately positioned in the neutral position.

[0041] The process of grasping and transferring the depleted battery box 500 is as follows: The telescopic arm assembly 12 is extended towards the battery swapping area 300. Before the telescopic arm is fully extended and grasps the depleted battery box 500, the controller drives the drive component 1222 to its maximum extension or maximum retraction state, so that the end of the swing arm 1221 near the battery swapping equipment 100 is lower than the far end, forming a preset posture with an inner bottom and an outer top, which counteracts the influence of the telescopic arm's heavy-load deflection. Subsequently, the gripper 13 grasps the depleted battery box 500 on the vehicle 400 and performs a lifting operation. When the battery swapping robot 1 is equipped with the aforementioned angle sensor, during the lifting process, the angle sensor detects the tilt angle of the swing arm 1221 in real time and feeds back a signal. The controller of the battery swapping station fine-tunes the action of the drive component 1222 according to the deviation to ensure that the battery box 500 does not tilt or has a very small tilt angle. Then, the telescopic arm assembly 12 is controlled to retract and extend towards the charging area 200 to transfer the depleted battery box 500 to the charging area 200.

[0042] Lowering the depleted battery box 500 and grasping the fully charged battery box 500: During the process of the telescopic arm assembly 12 extending to one side of the charging area 200, the extension direction of the telescopic arm changes, so the tilt angle of the swing arm 1221 needs to be adjusted accordingly. This can control the drive component 1222 to move in the opposite direction to the limit position, so that when the battery box 500 is in the charging area 200, it is basically in a horizontal state. After the lowering is completed, the drive component 1222 returns to the middle position, and the gripper 13 returns to the horizontal and grasps the fully charged battery box 500 in the charging area 200.

[0043] Transporting and installing a fully charged battery box 500: The telescopic arm assembly 12 is controlled to retract and extend again toward the battery swapping area 300. Similarly, before lifting the fully charged battery box 500, the drive component 1222 moves to the corresponding limit state to offset the deflection and lifts the battery box 500. Before transporting the battery box 500 to the target vehicle 400 in the battery swapping area 300, the drive component 1222 is adjusted in the opposite direction to the limit position so that the battery box 500 is basically in a horizontal state when it is in the battery swapping area 300, so that it can be accurately lowered and installed in place to complete a single battery swapping operation.

[0044] Repeating the above steps enables continuous battery swapping for multiple vehicles (400 units). The drive unit 1222 automatically switches between neutral and extreme states based on no-load and heavy-load conditions, while the leveling mechanism 122 coordinates throughout the process to ensure stable operation.

[0045] The method clearly defines the leveling operations at each key node of grasping, lowering, and transporting. Deflection is preemptively offset by the state switching of the drive component 1222, and real-time fine-tuning is achieved with the feedback from the angle sensor, ensuring the battery box 500 maintains a stable posture throughout the entire process. This effectively avoids docking deviations and component damage caused by tilting, improving the success rate of battery swapping. The drive component 1222 does not require complex stepless adjustment; it only needs to switch between mid-position and extreme states to meet the operating requirements, reducing the time spent on posture adjustment. The above steps are tightly integrated, enabling cyclical battery swapping of multiple vehicles 400, aligning with the goals of efficient and continuous operation of battery swapping stations. This application automatically controls the extension and retraction of the telescopic arm, the state switching of the drive component 1222, and the movement of the leveling mechanism 122 via a controller, eliminating the need for manual intervention in posture adjustment, reducing manual operation errors and labor intensity, adapting to unmanned battery swapping scenarios in mines, and reducing safety risks.

[0046] Optionally, the battery swapping methods at the battery swapping station include: Step S1: The telescopic arm assembly 12 extends so that the gripper 13 is located in the battery swapping area 300. The gripper 13 grabs the battery box 500 on the vehicle 400. The leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 near the battery swapping equipment 100 is lower than the end away from the battery swapping equipment 100. The battery swapping robot 1 lifts the telescopic arm assembly 12 and hoists the battery box 500 on the vehicle 400. In this step, the depleted battery box 500 is grasped and lifted. The telescopic arm assembly 12 is extended towards the battery swapping area 300 until the gripper 13 moves above and aligns with the battery box 500 of the target vehicle 400 in the battery swapping area 300. The gripper 13 then closes to grasp the depleted battery box 500 on the vehicle 400. Subsequently, the leveling mechanism 122 drives the swing arm 1221 to rotate, so that the end of the swing arm 1221 closer to the battery swapping equipment 100 is lower than the end farther away from the battery swapping equipment 100, completing the attitude pre-adjustment to counteract the heavy-load deflection of the telescopic arm; the battery swapping robot 1 lifts the telescopic arm assembly 12 and smoothly lifts the depleted battery box 500.

[0047] During the lifting process, the tilt angle of the swing arm 1221 can be detected in real time with the help of an angle sensor. The controller fine-tunes the action of the drive component 1222 based on the feedback signal to ensure the stability of the battery box 500.

[0048] Step S2: The telescopic arm assembly 12 drives the battery box 500 to extend to one side of the charging area 200. The leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 near the battery swapping device 100 is lower than the end away from the battery swapping device 100. The battery swapping robot 1 moves the telescopic arm assembly 12 down to unload the battery box 500 into the charging area 200. In this step, because the telescopic arm assembly 12 drives the battery box 500 to extend to the other side, the extension direction of the telescopic arm assembly 12 changes. In step S2, when the telescopic arm assembly 12 drives the battery box 500 to move past the battery swapping equipment 100, at this equilibrium position, the telescopic arm assembly has small deformation and the drive component 1222 has small load. It can move in the opposite direction to the limit position, that is, to the limit retraction state or the limit extension state, which is the opposite of the state in step S1.

[0049] Step S3: The telescopic arm assembly 12 moves the gripper 13 to the top of the fully charged battery box 500 on the charging area 200 and grabs the fully charged battery pack. The leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 near the battery swapping device 100 is lower than the end away from the battery swapping device 100. The battery swapping robot 1 lifts the telescopic arm assembly 12 and hoists the fully charged battery box 500. The first step involves lowering the depleted battery box 500 and grabbing the fully charged battery box 500: the telescopic arm assembly 12 extends to the corresponding position in the charging area 200. Before lowering the depleted battery box 500, the drive component 1222 is kept in its limit state to maintain the battery box 500 horizontal. After the lowering is completed, the drive component 1222 returns to the middle position, and the gripper 13 returns to horizontal to facilitate the smooth grabbing of the fully charged battery box 500 in the charging area 200.

[0050] Step S4: The telescopic arm assembly 12 drives the gripper 13 to extend to one side of the battery swapping area 300. The leveling mechanism 122 adjusts the swing arm 1221 to rotate so that the end of the swing arm 1221 closer to the battery swapping equipment 100 is lower than the end farther away from the battery swapping equipment 100. The battery swapping robot 1 moves the telescopic arm assembly 12 down to unload the fully charged battery box 500 onto the vehicle 400.

[0051] This step involves the transfer and installation of the fully charged battery box 500: the telescopic arm assembly 12 is controlled to retract and then extend again towards the battery swapping area 300. Similarly, before lifting the fully charged battery box 500, the drive component 1222 moves to its corresponding limit state to counteract deflection, ensuring that the fully charged battery box 500 is smoothly transferred to the undercarriage of the target vehicle 400 in the battery swapping area 300, accurately lowered and installed in place, completing a single battery swapping operation. The drive unit 1222 has a limit elongation state, a limit retraction state, and a neutral state; In steps S1 and S4, the drive member 1222 moves to its limit extension state or limit retraction state, so that the end of the swing arm 1221 near the power exchange device 100 is lower than the end away from the power exchange device 100. In steps S2 and S3, the drive member 1222 moves to the limit retraction state or the limit extension state, so that the end of the swing arm 1221 near the power exchange device 100 is lower than the end away from the power exchange device 100. In steps S1 and S4, the tilt state of the rocker arm that needs to be adjusted is the same. In steps S2 and S3, the state of the rocker arm that needs to be adjusted is the same but different from that in step S1. The same drive unit 1222 can be controlled to either limit extension or limit retraction in these different states, making control relatively simple.

[0052] Between steps S2 and S3, the drive component 1222 is moved to the neutral position, causing the swing arm 1221 to rotate parallel to the telescopic arm assembly 12's telescopic direction, so that each sling 123 is subjected to balanced force and its service life is extended.

[0053] Example 2 like Figures 1 to 11As shown in Embodiment 2 of this disclosure, the telescopic arm assembly 12 includes: multiple support arms 121, a leveling mechanism 122, and multiple slings 123. The support arms 121 are arranged sequentially, with adjacent support arms 121 slidably connected. The leveling mechanism 122 includes a swing arm 1221 and a drive member 1222. The middle portion of the swing arm 1221 is rotatably connected to the support arm 121 at the tail end. The drive member 1222 is disposed on the support arm 121 at the tail end. The drive member 1222 and the swing arm 1221 are in a transmission cooperation, driving the swing arm 1221 to swing and adjust the relative angle between the swing arm 1221 and the support arm 121. Each sling 123 is connected to both ends of the swing arm 1221. Each sling 123 is connected to a gripper 13, which is used to grip or release the battery box 500.

[0054] The leveling mechanism 122 includes two swing arms 1221, which are spaced apart. The rotation axes of the two swing arms 1221 can be located on the same straight line. Thus, both ends of the two swing arms 1221 are connected to slings 123, forming four slings 123, which can be easily connected to the four corners of the gripper 13, which is beneficial for the stable lifting of the battery box 500.

[0055] This application provides a leveling mechanism 122 at the end of the telescopic arm assembly 12, consisting of a swing arm 1221 and a drive component 1222. The middle part of the swing arm 1221 is rotatably connected to the tail support arm 121. The drive component 1222 is in a transmission cooperation with the swing arm 1221 to drive its swing, thereby adjusting the height of the slings 123 at both ends of the swing arm 1221. This design can specifically solve the unevenness problem of the existing battery swapping robot 1 lifting device caused by heavy load, deflection, manufacturing errors, etc., accurately leveling the transferred battery box 500, and making it as horizontal as possible for the battery box 500 to maintain a horizontal state throughout the lifting, lowering and transfer process. This effectively avoids the battery box 500 tilting and causing damage such as squeezing and bumping to the connector on the base, ensuring the connection stability and service life of the connector, and reducing the cost of parts replacement.

[0056] In existing technologies, the four independent slings 123 are prone to diagonal overload and uneven stress, leading to accelerated wear and increased risk of breakage. This application addresses this by using a swing arm 1221 to link the slings 123 at both ends. During leveling, the stress on both slings 123 can be adjusted synchronously, ensuring that each sling 123 evenly bears the 500kg weight of the battery box. This prevents damage to localized slings 123 due to overload, significantly extending their service life and reducing the risk of safety accidents caused by sling 123 malfunctions, thus improving the safety of battery swapping operations.

[0057] The leveling mechanism 122 of this application achieves leveling function through a simple cooperation between the swing arm 1221, the drive component 1222, and the tail support arm 121. It has a compact structure, occupies little space, and can flexibly adapt to a telescopic structure where multiple support arms 121 are sequentially slidably connected, without interfering with the sliding and telescopic movements of the support arms 121. The drive component 1222 is directly installed on the tail support arm 121, resulting in a short transmission path and rapid response. It can quickly adjust the relative angle between the swing arm 1221 and the support arm 121 according to operational requirements, adapting to the bidirectional telescopic operation of the battery swapping robot 1 between the charging base inside the box and the mining truck base outside the box, making it highly practical.

[0058] The horizontal battery box 500 in this application ensures precise alignment between the lifting device and the battery box 500, avoiding positioning detection deviations caused by tilting. This guarantees smooth docking of the battery box 500 and the base during battery swapping, significantly improving the success rate and operational efficiency, and meeting the core operational requirements of automated battery swapping stations. Simultaneously, the uniform force distribution and stable leveling effect reduce mechanical vibration and wear during operation, improving the overall operational stability and service life of the battery swapping robot 1, and lowering equipment maintenance costs.

[0059] In some possible implementations, the drive member 1222 is telescopic and is connected to the rocker arm 1221 and the support arm 121 respectively. The telescopic movement of the drive member 1222 can drive the rocker arm 1221 to rotate.

[0060] The leveling mechanism 122 is the core structure for achieving horizontal adjustment of the battery box 500. It includes a swing arm 1221 and a drive component 1222, both integrated on the support arm 121 at the tail end. The layout is reasonable and does not interfere with the sliding extension and retraction of the support arm 121. The swing arm 1221 is rotatably connected to the tail support arm 121 with its middle section as the pivot point, allowing it to swing bidirectionally around this pivot point, thereby changing the height positions of both ends of the swing arm 1221. The drive component 1222 provides the power source for the leveling action. It has a telescopic function, with its two ends connected to the swing arm 1221 and the tail support arm 121 respectively. Through its own telescopic movement, it generates power, precisely driving the swing arm 1221 to swing bidirectionally around the middle pivot point, thereby adjusting the relative angle between the swing arm 1221 and the support arm 121, achieving dynamic adjustment of the height at both ends of the swing arm 1221.

[0061] Regarding the specific type of drive component 1222, it can be flexibly selected according to the needs of the actual operation scenario, including but not limited to hydraulic cylinders, pneumatic cylinders, and electric push rods. Among them, hydraulic cylinders are suitable for heavy-duty operation scenarios, with strong power output and high stability; pneumatic cylinders have fast response speed and are suitable for scenarios with high operation efficiency requirements; electric push rods have high control precision and low energy consumption, and are suitable for highly automated operation environments. Multiple options can cover the usage needs of different mine battery swapping scenarios.

[0062] Each sling 123 is connected to one end of the swing arm 1221, forming a symmetrical suspension structure. The end of the sling 123 furthest from the swing arm 1221 is used to connect to the lifting device or directly hook the battery box 500. When the drive unit 1222 extends and retracts to drive the swing arm 1221 to swing, the two ends of the swing arm 1221 will produce opposite height changes. That is, when one end of the sling 123 rises with the end of the swing arm 1221, the other end of the sling 123 falls accordingly with the end of the swing arm 1221, thereby quickly correcting the posture of the suspended battery box 500 and solving the problem of uneven lifting device height.

[0063] In some possible implementations, the drive element 1222 is located at one or both ends of the rocker arm 1221 along its length.

[0064] The drive component 1222 of this application can be selectively arranged at one or both ends of the swing arm 1221 to provide customized leveling solutions for different operating scenarios: when arranged at one end, the structure is simpler and the cost is lower, which is suitable for conventional leveling needs; when arranged at both ends, the swing arm 1221 can be improved in terms of swing stability, adjustment accuracy and power output capability through the coordinated action of dual drives, which is suitable for harsh scenarios such as heavy load and high-precision docking, taking into account both economic and high performance requirements and broadening the scope of product application.

[0065] Single-end drive enables rapid attitude correction with low response lag; two-end drive, through coordinated control, can accurately compensate for attitude deviations caused by heavy loads and deflection, preventing the battery box 500 from tilting. Both arrangements ensure that the battery box 500 remains level throughout the lifting, moving, and docking process, effectively avoiding damage to the base connector from squeezing and bumping due to tilting, ensuring connector connection stability, extending its service life, and improving the success rate of battery swapping docking and overall operational efficiency.

[0066] When the drive component 1222 is arranged at one end, the lifting cable 123 is evenly stressed through the linkage of the swing arm 1221, avoiding local overload. When arranged at both ends, the dual drive works together to balance the stress on the swing arm 1221, reducing single-end load concentration and lowering the wear and failure risk of the drive component 1222 and the swing arm 1221. At the same time, the stable connection between the drive component 1222, the swing arm 1221, and the support arm 121, combined with the flexible arrangement, improves the overall rigidity of the leveling mechanism 122, making it suitable for heavy-duty operations in mines and preventing safety accidents such as the lifting cable 123 breaking or the battery box 500 falling.

[0067] When both ends of the swing arm 1221 are equipped with driving components 1222, the two driving components 1222 move in opposite directions. When one driving component 1222 extends, the other driving component 1222 retracts. When arranged at both ends, a reverse linkage design (one extends and one retracts) can be adopted. Through the dual-drive reverse coordinated action, the swing angle of the swing arm 1221 can be precisely controlled, significantly improving the stability, adjustment accuracy, and power output capability of the swing arm 1221. This makes it suitable for harsh scenarios such as heavy loads and high-precision docking, balancing economic efficiency and high performance requirements, and broadening the product's application range.

[0068] In some possible implementations, a notch 12212 is provided at the end of the swing arm 1221 along its length. The notch 12212 is located on the lower side of the swing arm 1221 and is generally shaped like a gap, providing clearance for the installation and movement of the drive member 1222. A hinge groove 12211 is correspondingly provided at the end of the swing arm 1221. The hinge groove 12211 communicates with the notch 12212. The end of the drive member 1222 extends into the notch 12212 and is rotatably connected to the hinge groove 12211. Specifically, the connection can be achieved by a pin passing through the hinge groove 12211 of the swing arm 1221 and the end of the drive member 1222, so as to achieve a hinged engagement between the two and ensure that the drive member 1222 can rotate flexibly relative to the swing arm 1221 during extension and retraction without jamming or interference. Meanwhile, the end of the drive component 1222 away from the swing arm 1221 can be hinged to the support arm 121, so that both ends of the drive component 1222 are rotatably connected, adapting to the angle changes during the swing of the swing arm 1221 and ensuring smooth power transmission.

[0069] In some possible implementations, the drive component 1222 is located on the side of the sling 123 opposite to the rotation axis of the swing arm 1221. The distance between the fulcrum (rotation axis) of the drive component 1222 and the swing arm 1221 is greater than the distance between the fulcrum of the sling 123 and the swing arm 1221. This significantly increases the driving torque through the lever principle, effectively reducing the power output load of the drive component 1222 when it drives the swing arm 1221 to swing, thus reducing wear and energy consumption. Especially in heavy-duty battery swapping scenarios, the drive component 1222 can more easily overcome the resistance caused by the weight and deflection of the battery pack 500, enabling the swing arm 1221 to rotate smoothly and quickly, preventing the drive component 1222 from malfunctioning due to excessive load, and further improving the operational reliability and service life of the leveling mechanism 122.

[0070] In some possible implementations, such as Figure 6As shown, two limiting members 1212 are provided on the support arm 121 at the tail end. The two limiting members 1212 are arranged sequentially along the length direction of the swing rod 1221, and are respectively located on both sides of the rotation axis of the swing member. When the swing rod 1221 swings to its limit angle, it abuts against the limiting members 1212. The limiting members 1212 restrict the rotation range of the swing rod 1221. The limiting members 1212 may include a limiting frame and a polymer material mounted on the limiting frame, which can buffer and absorb vibration.

[0071] Two limiting components 1212 are respectively located on both sides of the rotation axis of the swing arm 1221, which can limit the maximum swing angle of the swing arm 1221, avoid excessive swing of the swing arm 1221 due to excessive movement of the drive component 1222, sudden load changes, etc., prevent the sling 123 from being pulled, damage to the drive component 1222, or loss of attitude of the battery box 500, and structurally avoid overload risks, ensuring the safety and controllability of the entire battery swapping operation. The limiting component 1212 integrates polymer material, which can effectively absorb impact energy and buffer vibration when the swing arm 1221 stops and stops, avoid rigid collision between the swing arm 1221 and the limiting component 1212, reduce component wear and fatigue damage, and at the same time reduce the impact of vibration on leveling accuracy and power transmission stability, further adapting to the harsh working environment of heavy load and multiple impacts in mines, and extending the overall service life of the leveling mechanism 122.

[0072] In some possible implementations, such as Figure 6 As shown, the telescopic arm assembly 12 includes a hinge seat 1213, which is located at the tail end of the support arm 121. A swing arm 1221 is hinged to the hinge seat 1213 at its middle section. A limiting member 1212 is located between the sling 123 and the hinge seat 1213. The distance between the fulcrum of the limiting member 1212 and the swing arm 1221 is less than the distance between the sling 123 and the fulcrum of the swing arm 1221, which helps to reduce the force between the limiting member 1212 and the swing arm 1221, reducing the risk of impact damage. The distance between the fulcrum of the limiting member 1212 and the swing arm 1221 is less than the distance between the sling 123 and the fulcrum, significantly reducing the force exerted by the swing arm 1221 when it stops and is limited by lever principle. This prevents deformation or damage to the swing arm 1221 and the limiting member 1212 due to excessive impact force. Simultaneously, the buffering and vibration-absorbing effect of the polymer material forms double protection, further improving the structural reliability of the leveling mechanism 122.

[0073] In some possible implementations, a sling seat 12213 is provided on the swing arm 1221, and the sling 123 is rotatably connected to the sling seat 12213 by a pin. The sling seat 12213 has two spaced-apart arms, and the sling 123 can be a chain, which includes multiple links, with the end links located between the two arms, and the pin passing through the end links.

[0074] In some possible implementations, the telescopic arm assembly 12 includes an angle sensor mounted on the support arm 121 at the tail end. The angle sensor detects the swing angle of the swing arm 1221. The core principle of the angle sensor detecting the angle of the swing arm 1221 is to capture the real-time attitude change of the swing arm 1221 relative to the support arm 121 / hinge seat 1213 and convert it into a recognizable electrical signal. For example, the angle sensor can adopt a potentiometer-type structure, with the sensor's detection shaft linked to the swing arm 1221 via connecting rods, gears, or other transmission components. When the swing arm 1221 swings around the hinge seat 1213, it drives the sensor's detection shaft to rotate synchronously, causing the resistive element and brush inside the potentiometer to shift relative to each other, resulting in a change in the output resistance value. By converting the resistance change into a corresponding angle value through a controller, the swing angle of the swing arm 1221 can be accurately obtained. This method features a simple structure, strong anti-interference capability, and suitability for heavy-duty and high-vibration environments in mines. The angle sensor employs a non-contact detection principle (suitable for heavy-duty, anti-interference requirements in mining). It is mounted on the support arm 121, with a magnet installed at the corresponding position on the swing arm 1221. When the swing arm 1221 swings, the magnetic field direction of the magnet relative to the sensor changes. The sensor captures this change and converts it into an electrical signal, which is transmitted to the control module in real time. The control module compares the detected angle value with the horizontal target value (0°) to calculate the deviation and automatically drives the drive component 1222 to correct the angle of the swing arm 1221, forming a closed-loop leveling system of "detection-calculation-execution-feedback".

[0075] This application also provides a battery swapping robot 1, including: a main body 11, a gripper 13 and the above-mentioned telescopic arm assembly 12. The support arm 121 at the head end of the telescopic arm assembly 12 is connected to the main body 11. The main body 11 can move up, down and translate. The gripper 13 is connected to the sling 123 on the telescopic arm assembly 12.

[0076] Example 3 like Figures 4 to 11As shown in the figure, this embodiment three provides a more detailed description of the telescopic arm assembly, which includes: a plurality of support arms 121, at least a portion of the support arms 121 having a sliding groove 1211, the sliding groove 1211 extending along the telescopic direction of the support arm 121, at least a portion of the support arms 121 having a plurality of rollers 1214, each roller 1214 being arranged sequentially along the telescopic direction of the support arm 121, at least a portion of the support arms 121 having a plurality of support bodies, the center of each roller 1214 on the support arm 121 being located on a central line, the support bodies on the support arm 121 being located on one or both sides of the central line along the thickness direction of the support arm 121, the thickness direction being perpendicular to the telescopic direction of the support arm 121, the support arms 121 being arranged sequentially, and the roller 1214 of one of two adjacent support arms 121 being able to support the sliding groove 1211 of the other. During the extension of the telescopic arm assembly, a portion of the rollers 1214 of the next-level support arm 121 extends out of the groove 1211 of the previous-level support arm 121 before the support body. During the retraction of the telescopic arm assembly, the support body of the next-level support arm 121 slides into the groove 1211 of the previous-level support arm 121 before a portion of the rollers 1214.

[0077] In this design, during the retraction of the telescopic arm assembly, the support body slides into the groove 1211 of the upper-level support arm 121 before the roller 1214, which can raise the lower-level support arm 121 in advance, allowing the roller 1214 to smoothly transition into the groove 1211. This fundamentally avoids hard metal impact between the roller 1214 and the groove 1211. During the extension of the telescopic arm assembly, the support body remains in the groove after part of the roller 1214 has extended out of the groove 1211, continuing to provide support. This prevents the roller 1214 from dropping significantly and the tail of the support arm 121 from tilting upwards due to the cantilever effect. This avoids impact noise caused by structural displacement and collisions during the process, and significantly reduces the overall noise of the telescopic arm assembly during operation.

[0078] In the application, during the retraction of the telescopic boom assembly, the roller 1214 and the slide groove transition smoothly, eliminating the instantaneous impact load caused by hard impacts and preventing structural damage to core components such as the support arm 121, the slide groove 1211, and the roller 1214. During the extension of the telescopic boom assembly, the continuous support from the support body effectively prevents the roller 1214 from dropping significantly and the tail of the support arm 121 from tilting upwards due to the cantilever effect, reducing wear and fatigue losses of various components and improving the overall structural stability and durability of the telescopic boom assembly.

[0079] In some possible implementations, each of the supports includes a lower support 1215a, which is disposed on one side of the support arm 121 along the thickness direction, i.e. the lower side, located below the center line, for supporting and cooperating with the lower edge of the slide groove 1211. Each roller 1214 on the support arm 121 is disposed on both sides of the lower support 1215a along the extension and retraction direction of the support arm 121.

[0080] In this design, the support body includes a lower support body 1215a, which is arranged on the lower side of the support arm 121 along the thickness direction and is adapted to support the lower edge of the slide groove 1211. Rollers 1214 are respectively located on both sides of the lower support body 1215a in the extension / retraction direction. Coordinating with the action sequence of "when retracting, the lower support body 1215a slides into the slide groove 1211 before some of the rollers 1214; when extending, some of the rollers 1214 extend out of the slide groove 1211 before the lower support body 1215a," the lower support body 1215a... The support arm 121 can be raised in advance to allow the roller 1214 to smoothly transition into the slide groove 1211, eliminating the metal impact noise between the roller 1214 and the slide groove 1211 from the source. When extending, after part of the roller 1214 has extended, the lower support body 1215a remains in the slide groove 1211 and cooperates with the lower edge of the slide groove 1211 to prevent the roller 1214 from falling and the tail of the support arm 121 from tilting upward due to the cantilever effect, thus completely avoiding the impact noise of this process and achieving low-noise operation throughout the extension and retraction process.

[0081] In some possible implementations, each of the support bodies includes an upper support body 1215b, which is disposed on the other side of the support arm 121 along the thickness direction, i.e., the upper side, located above the center line, for supporting and cooperating with the upper edge of the slide groove 1211. The upper support body 1215b is disposed at one or both ends of the support arm 121 along the extension direction. The upper support body 1215b can press down on the support arm 121 to prevent collisions between the lower-level support arm 121 and the upper-level support arm 121 during the extension and retraction movement, thus avoiding significant noise.

[0082] For example, such as Figure 11As shown, the upper support body 1215b includes an inner upper support body 1215b1 and an outer upper support body 1215b2. When the telescopic arm assembly extends to its maximum length, the inner upper support body 1215b1 is located in the corresponding slide groove 1211, and the outer upper support body 1215b2 is located outside the slide groove 1211. Regardless of whether the support arm 121 extends or retracts, the inner upper support body 1215b1 is always located within the slide groove 1211 of the previous level support arm 121, while the outer upper support body 1215b2 can extend or retract from the slide groove 1211. The inner upper support body 1215b1 and the outer upper support body 1215b2 are respectively located at both ends of the support arm 121 along the extension direction, and the outer upper support body 1215b2 is located between the two rollers 1214. The outer upper support 1215b2 is located near the end of the support arm 121. During the retraction of the telescopic arm assembly, the outer upper support 1215b2 slides into the corresponding groove 1211 before some of the rollers 1214 (such as the end rollers). The outer upper support 1215b2 is used to support and cooperate with the upper edge of the groove 1211 of the previous level support arm 121 when the support arm 121 is almost fully retracted, pressing down on the next level support arm 121 and preventing the end rollers 1214 of the next level support arm 121 from colliding with the upper edge of the groove 1211 due to the upward tilt of the end. When the telescopic arm is extended to half its length, there is a problem of the inner end tilting upward. By setting the inner upper support 1215b1, it can be made at the upper edge of the groove 1211 to prevent the inner end of the telescopic arm from colliding with the inner wall of the groove 1211.

[0083] In some possible implementations, such as Figure 7 and Figure 8 As shown, the support body has a support surface 121511 and a first guide slope 121512. The first guide slope 121512 is located at both ends of the support surface 121511 along the extension and retraction direction of the support arm 121. In the direction from the support surface 121511 to the first guide slope 121512, the distance between the first guide slope 121512 and the plane containing the support surface 121511 gradually increases. During the retraction of the support arm 121, the first guide slope 121512 and the groove 1211 fit precisely and smoothly, completely avoiding obvious collisions between the support body and the groove 1211, further eliminating noise generated by structural contact, and achieving no obvious abnormal noise throughout the extension and retraction process.

[0084] In some possible implementations, the support surface 121511 is a flat surface, and the first guide slope 121512 and the support surface 121511 transition smoothly. When the support body is located in the groove 1211, the support body fits against the inner wall of the groove 1211. The roller 1214 and the inner wall of the groove 1211 have a line and surface contact. In this application, the support body and the groove 1211 adopt a surface-to-surface contact method. Compared with the existing line-to-surface contact between the roller 1214 and the groove 1211, the contact area is larger and the force is more uniform. Even if there are uneven processing or structural deformation on the actual track surface of the groove 1211, the support body and the groove 1211 can still be well fitted, effectively dispersing local stress and avoiding component damage caused by stress concentration. The smooth transition design of the flat support surface 121511 and the first guide slope 121512 ensures that there is no stress change during the support body entering the groove and supporting process, further optimizing the stress state. During the retraction of the support arm 121, the smooth guidance of the first guide ramp 121512 and the early lifting of the lower support body 1215a form a double protection, completely eliminating the instantaneous impact load generated by hard impact. During the extension, the continuous support of the lower support body 1215a and the lower edge of the slide groove 1211 avoids abnormal stress caused by the offset of the support arm 121 and the cantilever effect, reducing fatigue wear of various components. In this application, the support body is made of wear-resistant and high compressive strength polymer material, which not only improves the wear resistance and deformation resistance of the support body itself, but also absorbs the vibration load during the extension and retraction process through the buffering and shock absorption characteristics of the material, reducing the wear of metal components such as the slide groove 1211 and the roller 1214, and significantly extending the overall service life of the telescopic arm assembly.

[0085] In some possible implementations, the support body includes a support 12152 and a support member 12151. The support 12152 is fixedly connected to the support arm 121, and the support member 12151 is detachably connected to the support 12152. The support member 12151 is provided with a support surface 121511 and a first guide slope 121512. The support 12152 and the support arm 121 can be welded or connected by fasteners. The support member 12151 can be made of a wear-resistant, high-compressive-strength polymer material, which can effectively buffer and absorb shocks, avoid direct collisions between metal parts at the material level, further eliminate impact noise, and achieve no obvious abnormal noise throughout the telescopic process.

[0086] The support component 12151 can be made of polymer materials such as polytetrafluoroethylene (PTFE), ultra-high molecular weight polyethylene (UHMWPE), polyoxymethylene (POM), or nylon 66 (PA66). The aforementioned materials all have excellent wear resistance, high compressive strength, good self-lubrication, and shock absorption performance, which are suitable for the surface contact fit between the support component 12151 and the slide 1211, while effectively avoiding direct metal-to-metal collisions, thus balancing performance and service life. Alternatively, modified polymer composite materials with added glass fiber and carbon fiber can be selected to further enhance the deformation resistance and aging resistance of the support component 12151.

[0087] In some possible implementations, such as Figure 8 As shown, the support 12152 includes a main board 121521 and end heads 121522 located at both ends of the main board 121521. A groove is formed between the end heads 121522 and the main board 121521. A connection hole is provided on the main board 121521. The support member 12151 is partially embedded in the groove and partially protrudes from the groove. One end of the connector passes through the connection hole and is connected to the support member 12151, while the other end of the connector is confined to the main board 121521. The connector can be a bolt. The support member 12151 of this application is detachable, which facilitates replacement.

[0088] In some possible implementations, the groove 1211 has a second guide slope 12111 at its opening, so that during the process of the next-level support arm 121 extending or retracting the previous-level support arm 121, the first guide slope 121512 of the support body of the next-level support arm 121 can slide in contact with the second guide slope of the previous-level telescopic arm.

[0089] The groove 1211 has a second guide slope 12111 at its opening, and the support body has a first guide slope 121512. During the extension / retraction of the next-level support arm 121, the two can slide in precise contact, forming a bidirectional guiding structure. This provides smooth guidance for the support body's entry and exit from the groove, effectively preventing scraping, jamming, and hard collisions between the support body and the groove 1211. Combined with the timing of the actions of "the support body sliding into the groove 1211 before the roller 1214 during retraction and some of the rollers 1214 extending out of the groove 1211 before the support body during extension," and the surface-to-surface fit between the support body and the groove 1211, the transition of the roller 1214 and the extension and retraction of the support arm 121 are made more stable. This eliminates abnormal noises caused by metal impacts and structural collisions throughout the entire operation, achieving noiseless operation.

[0090] The sliding contact of the first and second guide ramps 12111 transforms the contact between the support and the slide 1211 from a rigid straight-face collision to a smooth ramp transition, effectively buffering the contact impact force during expansion and contraction and reducing damage to the structure from instantaneous loads. At the same time, the support and the slide 1211 adopt a surface-to-surface contact method, which has a larger contact area and more uniform force distribution compared to the line-to-surface contact between the roller 1214 and the slide 1211. Even if there are uneven processing or structural deformation on the two sides of the slide 1211 track, it can still ensure good fit, disperse local stress, and avoid stress concentration. In addition, the buffering and shock absorption characteristics of the polymer material support 12151, a multi-unloading system is constructed from the aspects of guidance, contact, and material, which greatly optimizes the stress state of each component.

[0091] The precise sliding cooperation between the first guide ramp 121512 and the second guide ramp 12111 provides precise trajectory guidance for the extension and retraction of the support arm 121, effectively preventing problems such as deviation, skewness, and jamming during the extension and retraction of the support arm 121, and ensuring the linearity and consistency of the extension and retraction action.

[0092] This embodiment also provides a battery swapping robot 1, including: a main body 11, a gripper 13 and the above-mentioned telescopic arm assembly, wherein the support arm 121 at the front end of the telescopic arm assembly is connected to the main body 11, and the gripper 13 is connected to the support arm 121 at the rear end of the telescopic arm assembly.

[0093] The battery swapping robot 1 of this application operates with low noise throughout the entire operation, improving the environmental friendliness of the operation. The battery swapping robot 1 is equipped with the aforementioned low-noise telescopic arm assembly. The telescopic movement of its gripper 13 is driven by this mechanism. During the entire battery swapping task, the telescopic arm assembly has no obvious abnormal noises from metal impact or structural collision, which greatly reduces the overall noise of the robot during operation, effectively avoids noise interference to the surrounding environment and staff, and improves the environmental friendliness of the battery swapping operation. It is especially suitable for battery swapping scenarios that are sensitive to noise, such as indoors, parks, and residential areas.

[0094] The battery swapping robot 1 of this application features a wear-resistant and impact-resistant mechanism, extending the overall service life of the robot. The telescopic arm assembly's multi-unloading design, wear-resistant material selection, and stable structural characteristics enable it to withstand the high-frequency, high-load operating conditions of the battery swapping robot 1, reducing component wear and failures caused by telescopic movements. The long service life of the telescopic arm assembly directly extends the maintenance cycle of the entire battery swapping robot 1, reducing robot downtime for maintenance, improving overall operating efficiency, and simultaneously reducing the cost of spare parts replacement and maintenance for the entire robot.

[0095] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A battery swapping station, characterized in that, include: A battery swapping device, comprising a battery swapping robot, the battery swapping robot having a telescopic arm assembly and a gripper, the free end of the telescopic arm assembly being provided with a leveling mechanism, the leveling mechanism comprising a swing arm and a drive component, the two ends of the swing arm being connected to slings, the gripper being connected to the slings, the drive component being kinetically connected to the swing arm to drive the swing arm to rotate and adjust the tilt angle of the swing arm; The charging area and the battery swapping area are located on both sides of the battery swapping equipment. The telescopic arm assembly can extend and retract in both directions, and can drive the gripper to move between the charging area and the battery swapping area to transfer the battery box between the battery swapping area and the charging area. Specifically, before the telescopic arm assembly extends to lift or unload the battery box, the drive unit drives the swing arm to rotate so that the end of the swing arm closer to the battery swapping device is lower than the end farther away from the battery swapping device.

2. The battery swapping station according to claim 1, characterized in that, The telescopic arm assembly includes a telescopic frame; The middle part of the swing arm is rotatably connected to the telescopic frame; The driving component is connected to the swing arm and the telescopic frame respectively. The driving component can extend and retract to drive the swing arm to rotate.

3. The battery swapping station according to claim 2, characterized in that, The drive component has a limit elongation state and a limit retraction state; Before the telescopic arm assembly extends to lift or unload the battery box, the drive unit moves to its maximum extension or maximum retraction state, so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device.

4. The battery swapping station according to claim 3, characterized in that, The drive unit also has a neutral position, in which the swing arm is parallel to the telescopic frame when the drive unit is moved to the neutral position.

5. The battery swapping station according to claim 1, characterized in that, The battery swapping robot has a main frame and a lifting frame; The lifting frame is vertically and flexibly connected to the main frame; The telescopic arm assembly is connected to the lifting frame at one end away from the leveling mechanism.

6. The battery swapping station according to any one of claims 1-5, characterized in that, The telescopic arm assembly includes multiple support arms, at least some of which have sliding grooves that extend along the telescopic direction of the support arm. At least some of the support arms have multiple rollers that are arranged sequentially along the telescopic direction of the support arm. At least some of the support arms have multiple support bodies that are arranged sequentially, with the center of each roller on the support arm located on a straight line. The support bodies on the support arm are located on one or both sides of the straight line along the thickness direction of the support arm, which is perpendicular to the telescopic direction of the support arm. The support arms are arranged sequentially, and the rollers of one of two adjacent support arms can be supported by the sliding groove of the other. The leveling mechanism is located on the support arm at the tail end. During the extension of the telescopic arm assembly, some rollers of the next-level support arm extend out of the groove of the previous-level support arm before the support body. During the retraction of the telescopic arm assembly, the support body of the next-level support arm slides into the groove of the previous-level support arm before some of the rollers.

7. The battery swapping method for a battery swapping station as described in any one of claims 1-6, characterized in that, include: Control the telescopic arm assembly to extend and retract, driving the gripper to move between the charging area and the battery swapping area, transferring the depleted battery pack from the vehicle to the charging area, and transferring the fully charged battery pack from the charging area to the vehicle. During the process of transferring the battery box using the telescopic arm assembly, the tilt angle of the swing arm is adjusted by the leveling mechanism to level the battery box.

8. The battery swapping method for a battery swapping station according to claim 7, characterized in that, The process of leveling the battery box during the transfer of the battery box by the telescopic arm assembly includes adjusting the tilt angle of the swing arm through the leveling mechanism to level the battery box. Before the telescopic boom assembly extends to lift the battery pack, the leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm closer to the battery swapping equipment is lower than the end farther away from the battery swapping equipment. Before the telescopic arm assembly extends to unload the battery box, the leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm closer to the battery swapping device is lower than the end farther away from the battery swapping device.

9. The battery swapping method for a battery swapping station according to claim 8, characterized in that, include: Step S1: The telescopic arm assembly extends so that the gripper is located in the battery swapping area. The gripper grabs the battery box on the vehicle. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm near the battery swapping equipment is lower than the end away from the battery swapping equipment. The battery swapping robot lifts the telescopic arm assembly and hoists the battery box on the vehicle. Step S2: The telescopic arm assembly drives the battery box to extend to one side of the charging area. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device. The battery swapping robot moves the telescopic arm assembly down to unload the battery box into the charging area. Step S3: The telescopic arm assembly moves the gripper to the top of the fully charged battery box in the charging area and grabs the fully charged battery pack. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device. The battery swapping robot lifts the telescopic arm assembly and hoists the fully charged battery box. Step S4: The telescopic arm assembly drives the gripper to extend to one side of the battery swapping area. The leveling mechanism adjusts the swing arm to rotate so that the end of the swing arm closer to the battery swapping equipment is lower than the end farther away from the battery swapping equipment. The battery swapping robot moves the telescopic arm assembly down to unload the fully charged battery box onto the vehicle.

10. The battery swapping method for a battery swapping station according to claim 9, characterized in that, The driving component has a limit elongation state, a limit retraction state, and a neutral state; In steps S1 and S4, the driving member moves to its maximum extension state or maximum retraction state, so that the end of the swing arm near the power swapping device is lower than the end away from the power swapping device. In steps S2 and S3, the drive member moves to its limit retraction state or limit extension state, so that the end of the swing arm near the battery swapping device is lower than the end away from the battery swapping device. In step S2, when the telescopic arm assembly drives the battery box to move past the battery swapping equipment, the driving component moves to the limit retraction state or the limit extension state. Between steps S2 and S3, the drive member is moved to the neutral position, causing the swing arm to rotate to be parallel to the extension direction of the telescopic arm assembly.

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