Battery quick change mechanism, vehicle, quick change method and thermal runaway protection method thereof

Abstract

This invention discloses a battery quick-swap mechanism, a vehicle, a quick-swap method, and a thermal runaway protection method. The battery quick-swap mechanism is a battery swapping frame structure, which includes a bottom frame for supporting the battery, an upper clamping structure for pressing and positioning the battery and capable of upward movement, and an end baffle that can be flipped open corresponding to the outer end of the battery on the bottom frame. When the battery pack experiences thermal runaway, a thermal runaway signal is sent to the vehicle's VCU unit. The VCU unit sends a command to the motor controller, which controls the end baffle drive motor and the upper pressure bar drive motor to operate. The battery pack is unlocked by opening the end baffle and the upper pressure bar driven by the corresponding motors. At this time, the explosion spring mechanism starts to work, and the kinetic energy of the explosion spring mechanism ejects the battery pack out of the battery swapping frame, realizing the separation of the thermal runaway battery pack from the vehicle and preventing further serious thermal runaway losses to the vehicle.

Description

Technical Field

[0001] This invention relates to the field of vehicle power battery technology, and in particular to a battery fast-swap mechanism, a vehicle, a fast-swap method, and a thermal runaway protection method thereof. Background Technology

[0002] With the development of the new energy vehicle industry, the market share of new energy vehicles is gradually increasing. Power lithium-ion batteries, with their advantages of high energy density, long lifespan, and environmental friendliness, are widely used in electric vehicles. Currently, there are two ways to supply electricity: charging and battery swapping. However, the current battery swapping system is complex and costly; moreover, the efficiency of replacing batteries during the swapping process is low, and its versatility is poor.

[0003] Mini trucks commonly use battery packs of models such as 60V45Ah and 60V30Ah. However, existing quick-swap mechanisms are not universal and typically employ a sealed structure for locking and securing, which is not conducive to heat dissipation during discharge. Furthermore, in the event of thermal runaway, the battery pack cannot be quickly and automatically detached from the vehicle, posing a significant safety hazard. For example, the quick-swap bracket and battery swapping vehicle containing it disclosed in patent CN 115991086A have poor versatility. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a battery quick-swap mechanism, a vehicle, a quick-swap method, and a thermal runaway protection method, aiming to achieve efficient battery replacement with good versatility.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: The present invention provides a battery quick-change mechanism, which is a battery swapping frame structure. The battery swapping frame structure includes a bottom frame for carrying the battery, an upper pressing structure for pressing and positioning the battery and being movable upward above the bottom frame, and an end baffle that can be flipped open corresponding to the outer end of the battery on the bottom frame.

[0006] Further or preferred: The upper pressing structure is an upper pressure bar, and the battery swapping frame structure is provided with an upward flipping drive structure for driving the upper pressure bar to flip upward.

[0007] The upward driving structure includes a flipping frame corresponding to the inner end of the battery, an upper pressure bar with its inner end located on the top of the flipping frame, and an upper pressure bar drive motor for driving the flipping frame to flip on the bottom frame.

[0008] The bottom frame is provided with a vertical plate corresponding to the inner end of the battery. The inner end of the upper pressure strip is hinged to the top of the vertical plate, and the outer end of the upper pressure strip is connected to a top rod. The bottom frame is provided with a lifting drive structure for lifting the top rod.

[0009] The lifting drive structure includes a motor base, an electric push cylinder, and a lifting slider. The electric push cylinder is located inside the motor base. The motor base has a guide hole for guiding the lifting slider. The lifting slider is located inside the guide hole and connected to the push rod of the electric push cylinder. The lifting slider has a horizontally arranged waist-shaped hole, and the push rod is located inside the waist-shaped hole.

[0010] A rubber pad or protrusion is provided below the upper pressure strip.

[0011] The lower end of the end baffle is hinged to the bottom frame via a rotating shaft, and the bottom frame is equipped with an end baffle drive motor for driving the rotating shaft to rotate.

[0012] The upper end of the end baffle and the outer end of the upper pressure strip are engaged by a snap-fit ​​connection.

[0013] The upper outer side of the end baffle is provided with a chamfer structure, and the lower part of the outer end of the upper pressure strip is provided with a protruding clip structure that is locked onto the chamfer structure.

[0014] The bottom frame is provided with a side baffle that is easy to pull out after the battery is unlocked. The side baffle has an L-shaped plate structure.

[0015] The battery swapping frame structure is equipped with an explosion spring mechanism at the inner end of the corresponding battery to eject the battery pack in case of thermal runaway.

[0016] The present invention provides a vehicle including the battery quick-swap mechanism, wherein two battery quick-swap mechanisms are arranged laterally opposite each other, and the outer end of the battery pack is arranged corresponding to one side of the vehicle.

[0017] This invention provides a battery quick-swap method for quickly swapping a vehicle battery pack using the aforementioned battery quick-swap mechanism, comprising the following steps: The upper clamping structure and end baffle are flipped to unlock the battery pack, which is then pulled out of the battery swapping frame structure for battery swapping.

[0018] This invention provides a battery thermal runaway protection method, comprising the following steps: When the battery pack experiences thermal runaway, a thermal runaway signal is sent to the vehicle's VCU unit. The VCU unit then sends a command to the motor controller, which in turn controls the end baffle drive motor and the upper pressure bar drive motor to operate. The battery pack is unlocked by opening the end baffle and upper pressure bar driven by the corresponding motors. At this time, the explosion spring mechanism starts to work, and the kinetic energy of the explosion spring mechanism ejects the battery pack out of the battery swapping frame, thus separating the thermal runaway battery pack from the vehicle.

[0019] Compared with the prior art, the present invention has the following advantages: The battery quick-swap mechanism, vehicle, quick-swap method, and thermal runaway protection method are reasonably designed. They adopt a battery swapping frame structure that is compatible with battery packs of different models and sizes. The design structure is simple, facilitates battery swapping operations, and has wide applicability. At the same time, through thermal runaway detection, after thermal runaway is detected, the upper pressure bar and buckle structure are released, and the explosion spring mechanism ejects the thermal runaway battery pack, preventing further serious thermal runaway damage to the entire vehicle. Attached Figure Description

[0020] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings: Figure 1 This is a schematic diagram of a battery quick-change mechanism according to the present invention.

[0021] Figures 2 to 4 This is a schematic diagram of another structure of the battery quick-change mechanism of the present invention.

[0022] Figure 5 This is a flowchart of the thermal runaway protection control process for the battery pack of the present invention.

[0023] In the picture: 1. Bottom frame, 2. Upper pressure strip, 3. Rubber pad, 4. End baffle, 5. Battery pack, 6. Side baffle, 7. End baffle drive motor, 8. Upper pressure strip drive motor, 9. Explosion spring mechanism, 10. Top rod, 11. Lifting slider, 12. Motor mount, 13. Electric push cylinder, 14. Vertical plate, 15. Transmission gear. Detailed Implementation

[0024] Although the invention has been shown and described herein with reference to specific embodiments, it is not intended to be limited to the details shown. Rather, various modifications in detail may be made within the equivalent scope and scope of the claims without departing from the invention. In the drawings, the same item numbers refer to the same elements.

[0025] Throughout this disclosure, various terms are used to describe the physical shape or arrangement of features. Many of these terms are used to describe features conforming to a cylindrical or generally cylindrical geometry with the feature as its radius and a central axis perpendicular to that radius. Unless otherwise specified, the terms are given the following meanings: The terms “longitudinal,” “longitudinal,” “axial,” and “axial” refer to a direction, dimension, or orientation parallel to the central axis. The terms “radial” and “radially” refer to a direction, dimension, or orientation perpendicular to the central axis. The terms “inward” and “inner” refer to a direction, dimension, or orientation extending radially toward the central axis. The terms “outward” and “outer” refer to a direction, dimension, or orientation extending radially away from the central axis.

[0026] In this specification, relative terms such as “horizontal,” “vertical,” “upward,” “downward,” “top,” and “bottom,” and their derivatives (e.g., “horizontal,” “downward,” “upward,” etc.) should be interpreted as referring to the direction described or the direction shown in the accompanying drawings. These relative terms are for ease of description and are not generally intended to require a specific direction.

[0027] Unless otherwise defined, all technical terms used in the embodiments of this application have the same meaning as commonly understood by those skilled in the art. Some technical terms appearing in the embodiments of this application are described below.

[0028] Mini trucks: Mini trucks are small and compact, maneuverable and easy to park, fuel-efficient, cost-effective, and have a moderate load capacity. They are suitable for daily short-distance cargo transport, urban and rural commuting, street vending and delivery, and commuting between parks and fields. They are lightweight, durable, and highly practical, making them convenient short-distance transport vehicles.

[0029] BMS System: BMS, or Battery Management System, is the intelligent steward of the power battery. It monitors the battery voltage, current, and temperature in real time, accurately estimates the remaining power, balances individual cells, protects against overcharge and over-discharge, and manages the charging and discharging logic to ensure battery safety and stability and extend its service life.

[0030] VCU Unit: The VCU is the vehicle controller, the core of the brain of new energy vehicles. It coordinates the power, drive, braking, energy recovery and the collaborative work of various components of the vehicle. It receives throttle and brake signals and coordinates the work of systems such as motor and battery BMS.

[0031] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and through the description of the examples.

[0032] The power battery pack is a core component of electric mini-trucks. Currently, there are two ways to supply electricity: charging and battery swapping. However, the current battery swapping method is complex, costly, inefficient in replacing batteries, and lacks versatility.

[0033] Furthermore, the battery pack is usually locked in a sealed structure, which is not conducive to heat dissipation during discharge. In the event of thermal runaway, the battery pack cannot be automatically separated from the vehicle quickly, which can easily lead to vehicle fires and poses a significant safety hazard.

[0034] To address the aforementioned technical issues, such as Figures 1 to 4 As shown, this application provides a battery quick-swap mechanism that enables rapid replacement of battery packs and is applicable to battery packs of various sizes and specifications. The battery swapping operation is simple, efficient, and versatile.

[0035] The battery quick-swap mechanism is a battery swapping frame structure, which is different from the traditional sealed battery pack quick-swap structure. The battery swapping frame structure is conducive to heat dissipation when the battery pack is working.

[0036] The battery swapping frame structure includes a bottom frame 1 for supporting the battery. The bottom frame 1 can be a square frame structure or directly adopt the chassis frame structure of the vehicle. The battery pack is supported and positioned by the frame structure, making the structure stable and reliable.

[0037] The bottom frame 1 has an upper clamping structure for pressing and positioning the battery and can move upward. The bottom frame 1 has an end baffle 4 that can be flipped open corresponding to the outer end of the battery. The battery pack is placed on the bottom frame. The upper part of the battery pack 5 is clamped and positioned by the upper clamping structure. The bottom frame is usually provided with an inner end baffle positioning structure corresponding to the inner end of the battery. The outer end of the battery pack is positioned by the end baffle. The inner end baffle and the end baffle are used to position the inner and outer ends of the battery pack respectively, and the positioning is reliable.

[0038] The inner end baffle on the bottom frame 1 is a fixed baffle, which is welded to the bottom frame. The fixed baffle can be designed to be a small baffle. When the battery pack is pushed into the battery swapping frame structure, the inner end of the battery pack abuts against the fixed baffle to achieve battery positioning. After the upper clamping structure and the end baffle are unlocked and opened, the battery pack swapping operation can be carried out. The operation is simple and improves the efficiency of battery swapping.

[0039] In some embodiments, the upper pressing structure is an upper pressing bar 2, and the battery swapping frame structure is provided with an upward flipping drive structure for driving the upper pressing bar to flip upward. The upper pressing bar is flipped upward by the upward flipping drive structure to unlock the upper part of the battery pack. Furthermore, a rubber pad or protrusion is provided below the upper pressure strip 2; by replacing the rubber pad or designing different sizes of protrusions, it can be compatible with battery packs of different heights and sizes, so that this battery swapping frame can be compatible with different models and sizes of battery packs, and has good versatility.

[0040] Optionally, such as Figure 1 As shown, the rubber pad 3 is a silicone pad, which is removable and replaceable. The silicone pad has mounting holes and is fixed by screws; or, the silicone pad has a groove on the top, and the upper pressure strip is interference-fitted into the groove to achieve a fit, making it easy to replace the silicone pad.

[0041] Optionally, such as Figures 2 to 4 As shown, the protrusions are set at the lower part of the upper pressure strip. Each upper pressure strip has a set of protrusions at the lower part, and there is a certain gap between adjacent protrusions. The size of the protrusions can be adapted to different models of battery packs. Furthermore, the protrusions are wrapped with rubber sleeves, which can effectively protect the battery pack, avoid the battery pack being subjected to concentrated force, and can effectively protect the battery pack. The upper pressure strip body and the protrusion are integrally molded, resulting in a stable and reliable structure. Different sizes and specifications of battery packs can be positioned by replacing different upper pressure strips. Alternatively, the upper pressure strip body and the protrusion can be set separately, with stepped holes on the protrusion. The protrusion is fixed to the lower part of the upper pressure strip by screws, and different models of battery packs can be positioned by replacing the protrusion.

[0042] In some embodiments, such as Figure 1 As shown, the upward drive structure includes a flipping frame corresponding to the inner end of the battery, an upper pressure bar 2 with its inner end located on the top of the flipping frame, and an upper pressure bar drive motor 8 for driving the flipping frame to flip on the bottom frame.

[0043] The flip frame has a square frame structure. The inner end of the battery pack is positioned by a small fixed baffle to avoid interference between the flip frame and the battery pack when the flip frame flips. The flip frame is formed by welding angle steel and a rubber pad is set on the inner side. The battery pack is limited by the edge of the angle steel, which is stable and reliable. The base frame 1 has a rotating shaft at the lower end of the flip frame. The lower end of the flip frame is fixedly connected to the rotating shaft. The upper pressure bar drive motor is located on the side of the flip frame and fixed on the base frame, and is connected to the end of the rotating shaft. The structure is compact.

[0044] The upper pressure strip 2 is a set of hollow square tubes arranged side by side; preferably, the upper pressure strip consists of two hollow square tubes, the inner ends of which are welded to the top of the flip frame, and the two hollow square tubes are connected by welding through a middle square tube, making the structure stable and reliable.

[0045] In some embodiments, such as Figure 1 As shown, the lower end of the end baffle is hinged to the bottom frame via a rotating shaft. The bottom frame is equipped with an end baffle drive motor 7 for driving the rotating shaft to rotate. The end baffle is rotated by the end baffle drive motor. When the end baffle is in the vertical position, the top of the end baffle and the end of the upper pressure strip are locked together by a snap-fit ​​structure. Then, the end baffle is used to position the outer end of the battery pack, which is stable and reliable.

[0046] In some embodiments, the bottom frame 1 is provided with a side baffle 6 for easy pulling out after the battery is unlocked; the side baffle has an L-shaped plate structure. Figure 1 As shown, the two side baffles are arranged opposite each other, forming a guide structure for battery installation and removal; facilitating battery swapping operations.

[0047] Preferably, the side baffle 6 is made of angle steel. The bottom of the angle steel provides reliable support for the battery pack, and the side of the angle steel limits the side of the battery pack, ensuring stable and reliable positioning of the battery pack. The two sides of a pair of side baffles form a guide channel, ensuring stable and reliable battery swapping.

[0048] In some embodiments, such as Figure 1As shown, two battery quick-swap mechanisms are set on the bottom frame 1. Each battery quick-swap mechanism positions the overall structure of a battery pack. There is a certain gap between the two battery quick-swap mechanisms to utilize the battery pack for heat dissipation.

[0049] Furthermore, the two battery quick-swap mechanisms are arranged laterally opposite each other, with the lateral arrangement along the Y-direction of the vehicle, i.e., along the lateral direction of the vehicle; the end baffle of one battery quick-swap mechanism is arranged corresponding to one side of the vehicle, and the end baffle of the other battery quick-swap mechanism is arranged corresponding to the other side of the vehicle, i.e., the outer ends of both battery packs are arranged facing the outside of the vehicle, which facilitates the battery swapping operation.

[0050] A spring mechanism is provided on the inner end of the fixed baffle corresponding to the battery pack. After the battery pack is installed, the spring mechanism is compressed and stores elastic potential energy. After the upper pressure bar and end baffle of the battery pack are flipped and unlocked, the battery pack pops out by the force of the elastic mechanism, which is convenient for replacement.

[0051] Preferably, the spring mechanism is an explosion spring mechanism 9, which can be a gas spring actuator or a deflagration spring mechanism from an automobile. After thermal runaway detection, the upper pressure bar and end baffle are unlocked, and the explosion spring mechanism ejects the thermal runaway battery pack to prevent further serious thermal runaway losses to the entire vehicle.

[0052] In some embodiments, a frame structure with replaceable silicone pads, different sized protrusions, or upper pressure strips is used to accommodate battery packs of various sizes and models. Different heights and specifications of batteries can be flexibly adapted by changing accessories, making it widely applicable. The traditional sealed battery swapping structure is abandoned in favor of an open battery swapping frame, with a gap reserved between the two quick-swap mechanisms to facilitate ventilation and heat dissipation during battery pack operation, reducing the risk of heat buildup.

[0053] The bottom frame, fixed inner end baffle, flip-up end baffle, upper clamping structure and L-shaped side baffle form a multi-directional limiting structure, which supports and positions the battery pack from the top, bottom, inside and outside and the sides, and the battery pack positioning is stable and reliable; the flip frame and upper pressure strip adopt a welded / integrated molding structure, and the overall structure has high strength and good stability.

[0054] The system features a motor-driven upper pressure bar and end baffle that automatically flip and unlock, forming a guide channel with the side baffles. The battery pack can be pushed in for installation and pulled out smoothly. An additional spring mechanism allows the battery pack to pop out automatically after unlocking, significantly simplifying the battery swapping process and improving efficiency. Both a standard spring structure and an explosion spring mechanism can be used simultaneously. During battery swapping, the standard spring ejects the battery pack normally, resulting in high efficiency. In the event of thermal runaway of the battery pack, the explosion spring mechanism instantly ejects the battery pack from the vehicle.

[0055] The rubber pads and protrusions under the upper pressure strip are wrapped in rubber sleeves to cushion and protect the battery pack from squeezing and bumping. Equipped with an explosion spring mechanism, the battery pack can be automatically ejected when thermal runaway is detected, blocking the spread of heat and avoiding the safety hazard of thermal runaway of the whole vehicle.

[0056] Each drive motor and shaft is integrated and arranged on the bottom frame and the side of the tilting frame, which makes high space utilization. The dual battery quick-swap mechanism is symmetrically arranged along the vehicle's transverse direction, with the outer end of the battery facing the outside of the vehicle, which facilitates independent battery swapping on both sides and effectively improves battery swapping efficiency.

[0057] Figure 1 This application describes a structure for a battery quick-change mechanism, and the above mainly provides a detailed introduction to this structural scheme. Figures 2 to 4 This application presents another structure for the battery quick-change mechanism. The following section provides a detailed description of this structural design, with specific details as follows: A battery swapping frame structure for a MINI truck is provided, which is used to fix the battery swapping pack and facilitates the removal and extraction of the battery swapping pack, saving costs and improving battery swapping efficiency. The passive heat dissipation performance of this frame structure is better than that of traditional closed battery swapping frames, which facilitates the heat dissipation of the battery pack during vehicle operation. At the same time, it can quickly eject the thermal runaway battery pack from the vehicle, avoiding further serious thermal runaway losses to the vehicle.

[0058] The bottom frame 1 is a square frame structure. The battery quick-swap mechanism is integrated on the bottom frame to form an overall battery swapping module structure. The overall battery swapping module structure is installed and fixed on the truck. The structure is compact and convenient for processing, manufacturing and installation.

[0059] Two battery quick-swap mechanisms are horizontally arranged on the bottom frame, and the two battery quick-swap mechanisms are symmetrically arranged on the left and right. Each battery quick-swap mechanism fixes the battery pack on one side. The vehicle's power battery is divided into two battery packs, which are fixed separately. The battery packs are smaller in size and weight than before, which facilitates battery swapping operations.

[0060] A vertical plate 14 is fixed at the middle of the horizontal position of the bottom frame. The vertical plate can be a steel plate structure. The lower end of the vertical plate is welded to the bottom frame. The bottom sides are reinforced by inclined plates, making the structure stable and reliable.

[0061] The top side of the upright plate 1 is provided with a set of side-by-side support ears; preferably, two support ears are arranged side-by-side with a certain distance between them; the inner end of the upper pressure strip 2 is hinged to the support ears, and the upper pressure strip can be flipped up to open for battery swapping. After battery swapping, the upper pressure strip can be pressed down to lock and fix the battery pack.

[0062] The bottom frame 1 has a flip-up end baffle 4 on the horizontal side corresponding to the outer end of the battery pack. The outer end of the battery pack is positioned by the end baffle, and the inner end of the battery pack is positioned by a fixed baffle fixed to the bottom frame.

[0063] The bottom frame 1 has a side pivot on the horizontal side. The lower end of the end baffle is connected to the side pivot. The end baffle drive motor 7 is fixed on the bottom frame and connected to the side pivot. The end baffle is driven to flip through the baffle drive motor.

[0064] A transmission gear structure is provided between the end of the baffle drive motor and the side rotating shaft; the transmission gear 15 includes a meshing driving gear and a driven gear. The driven gear is fixed on the end of the side rotating shaft, and the driving gear is connected to the output shaft of the baffle drive motor. The transmission gear structure increases the turning torque of the end baffle and avoids jamming.

[0065] The upper end of the end baffle and the outer end of the upper pressure bar are engaged by a snap-fit ​​mechanism; when the upper pressure bar and the end baffle are in the locked position, their ends are locked together by the snap-fit ​​mechanism, so as to achieve stable positioning of the battery pack by the upper pressure bar and the end baffle.

[0066] In some embodiments, preferably, the upper outer side of the end baffle is provided with a chamfered structure, and the lower part of the outer end of the upper pressure strip is provided with a protruding locking structure that engages with the chamfered structure; the chamfered structure is an arc-shaped structure, the end baffle first reaches the locking position, that is, it is driven to the vertical position by the baffle drive motor, the upper pressure strip flips downward, and the protruding locking structure at the end of the upper pressure strip engages with the chamfered structure to achieve locking and positioning, such as Figure 3 As shown.

[0067] The upper pressure bar is equipped with a pressure bar drive structure for driving the upper pressure bar to flip. The pressure bar drive structure drives the upper pressure bar to move downward to the locked position, thereby achieving positioning of the upper part of the battery pack. During battery swapping or in the event of battery pack thermal runaway, the pressure bar drive structure drives the upper pressure bar to move upward to unlock the battery pack positioning.

[0068] In some embodiments, a vertical plate is provided on the bottom frame corresponding to the inner end of the battery, the inner end of the upper pressure strip is hinged to the top of the vertical plate, the outer end of the upper pressure strip is connected to a top rod, and a lifting drive structure for lifting the top rod is provided on the bottom frame.

[0069] Optionally, the outer end of the upper pressure bar 2 is provided with a push rod 10, which extends outward; the lifting drive structure includes a motor base 12, an electric push cylinder 13, and a lifting slider 11. The electric push cylinder 13 is located inside the motor base 12. The motor base is provided with a guide hole for guiding the lifting slider. The lifting slider is located inside the guide hole and connected to the push rod of the electric push cylinder. The lifting slider has a horizontally provided waist-shaped hole, and the push rod is located inside the waist-shaped hole.

[0070] The motor mount 12 has a hollow box structure, and the electric push cylinder 13 is integrated inside the box. The structure is compact and can effectively protect the electric push cylinder.

[0071] The top surface of the motor mount 12 is provided with guide holes, which limit the lifting slider 11 to only move vertically up and down. The lifting slider is pushed up and down by an electric push cylinder.

[0072] In this embodiment, the inner end of the battery within the battery swapping frame structure is provided with an explosion spring mechanism for ejecting the battery pack in case of thermal runaway; the explosion spring mechanism is integrated into the bottom frame and located at the inner end of the battery pack; furthermore, the explosion spring mechanism can be integrated into the upright plate, resulting in a stable and reliable structure.

[0073] This battery swapping frame uses an upper pressure bar structure to lock and secure the battery pack, and a rear foot chain to control the angle of the upper pressure bar. The upper pressure plate and the end baffle are connected and secured to the battery pack by a locking mechanism. It can also be compatible with battery swapping packs of different heights and sizes by replacing silicone pads of different thicknesses or by setting protrusions of different sizes. Through thermal runaway detection, it determines the positioning of the battery pack after the pressure bar and the end baffle flip and contact after thermal runaway, and the explosion spring mechanism ejects the thermal runaway battery pack.

[0074] The present invention provides a vehicle including a chassis, on which a battery quick-swap mechanism is integrated. Two battery quick-swap mechanisms are arranged laterally opposite each other, and the outer ends of the battery packs are arranged corresponding to one side of the vehicle. The two battery packs are fixed in relatively independent positions, and the outer ends of the battery packs are both arranged facing the outside of the vehicle, which facilitates battery swapping operations.

[0075] The MINI truck's power battery swapping system utilizes a battery swapping frame structure. This structure comprehensively considers various aspects such as swapping efficiency, cost control, heat dissipation performance, safety protection, and structural stability. Compared to traditional battery swapping frame structures, it has significant technical advantages, is fully adaptable to the usage scenarios of the MINI truck, and offers convenient battery swapping operations with outstanding practicality and reliability.

[0076] Firstly, regarding the convenience and efficiency of battery swapping, the frame structure adopts an integrated design. The bottom square frame and the battery quick-swap mechanism are integrated to form an overall battery swapping module, which is then installed and fixed on the truck. This not only results in a compact structure, significantly reducing the difficulty of processing, manufacturing, and installation, and lowering production and assembly costs, but also allows for rapid positioning and fixing of the overall module. The battery quick-swap mechanism can be manufactured independently and then fixed to the vehicle, making it simple and efficient to manufacture. Simultaneously, two battery quick-swap mechanisms are symmetrically arranged laterally on the bottom frame, separating the vehicle's power battery into two independent battery packs and fixing them separately. This effectively reduces the volume and weight of a single battery pack, completely solving the problems of inconvenient handling and labor-intensive operation when swapping traditional single large battery packs. This significantly reduces the labor intensity of battery swapping workers and significantly improves the convenience of battery swapping operations and overall work efficiency.

[0077] Secondly, in terms of passive heat dissipation performance, this open frame structure breaks through the design limitations of traditional closed battery swapping frames. Through reasonable frame layout and structural design, it eliminates the obstruction of heat dissipation by the closed structure, allowing the battery pack to form good convection with the outside air. The passive heat dissipation performance is significantly improved compared to the traditional structure. It can not only meet the continuous heat dissipation needs of the battery pack during vehicle operation, effectively reduce the battery operating temperature, and avoid problems such as battery performance degradation and shortened life due to overheating, but also reduce the additional investment in the heat dissipation system, further control the overall cost, and at the same time provide reliable temperature protection for the stable operation of the battery pack, improving the safety and durability of battery use.

[0078] In terms of safety protection, the frame structure is equipped with a comprehensive thermal runaway response mechanism, specifically addressing the potential safety hazards to the entire vehicle caused by battery pack thermal runaway. An explosion spring mechanism is integrated within the frame corresponding to the inner end of the battery pack. The battery pack status can be monitored in real time through a thermal runaway detection system. Once thermal runaway of the battery pack is detected, the upper pressure bar and end baffle can be quickly driven to flip, releasing the positioning constraint on the battery pack. Subsequently, the explosion spring mechanism rapidly ejects the thermal runaway battery pack from the vehicle, fundamentally preventing the further spread of thermal runaway and effectively preventing serious thermal runaway losses to the entire vehicle. This maximizes the safety of the vehicle, passengers, and the surrounding environment, filling the gaps in the emergency handling of thermal runaway in traditional battery swapping frames and improving the overall safety level of the vehicle.

[0079] In terms of structural stability and positioning reliability, the frame structure incorporates multiple reinforcement designs. A steel plate upright fixed in the middle of the bottom frame is welded at the bottom and reinforced on both sides with inclined plates, significantly improving the load-bearing capacity of the upright and the overall structural stability. This provides a solid support foundation for the subsequent installation of components such as the upper pressure strip and battery pack. The lugs at the top of the upright are hinged to the upper pressure strip, and together with the pressure strip drive structure, the upper pressure strip can be flexibly flipped. During battery swapping, it can be flipped upwards to easily remove the battery pack, and after swapping, it can be pressed down to lock and stably position the battery pack at the top. The end baffles on the sides of the bottom frame are connected to the baffle drive motor via side pivots. Combined with the transmission gear structure, this allows for flexible flipping via motor drive for precise positioning of the battery pack's outer end, and also increases the flipping torque via gear transmission, effectively preventing jamming during the end baffle flipping process and ensuring smooth operation. Meanwhile, the outer end of the upper pressure strip and the upper end of the end baffle are locked together by a snap-fit ​​structure. The arc-shaped chamfer structure at the upper end of the end baffle is precisely matched with the convex snap-fit ​​structure at the outer end of the upper pressure strip. In the locked state, the two are tightly fitted together. Together with the bottom fixed baffle for positioning the inner end of the battery pack, a comprehensive positioning constraint is formed to ensure that the battery pack will not shift or shake during vehicle operation, thus ensuring driving safety.

[0080] Furthermore, this frame structure boasts excellent compatibility and versatility. By replacing silicone pads of different thicknesses or adding protrusions of different sizes, it can flexibly adapt to battery swapping packs of varying heights without requiring large-scale modifications to the main frame structure. This effectively reduces the cost of adapting to different battery pack specifications and enhances the frame's applicability and reusability. Simultaneously, the electric push cylinder in the pressure bar drive structure is integrated within the motor mount of the hollow box structure. This not only results in a compact structure and saves installation space but also effectively protects the electric push cylinder from damage caused by external dust, debris, and impacts, extending the lifespan of the drive components and reducing subsequent maintenance costs. Overall, this battery swapping frame structure organically combines convenient battery swapping, cost control, efficient heat dissipation, safety protection, and structural stability, effectively addressing many pain points of traditional battery swapping frames.

[0081] This invention provides a battery quick-swap method for quickly swapping a vehicle battery pack using the aforementioned battery quick-swap mechanism, comprising the following steps: The upper clamping structure and end baffle are flipped to unlock the battery pack, which is then pulled out of the battery swapping frame structure for battery swapping.

[0082] This invention provides a battery thermal runaway protection method, comprising the following steps: When the battery pack experiences thermal runaway, a thermal runaway signal is sent to the vehicle's VCU unit. The VCU unit then sends a command to the motor controller, which in turn controls the end baffle drive motor and the upper pressure bar drive motor to operate. The battery pack is unlocked by opening the end baffle and upper pressure bar driven by the corresponding motors. At this time, the explosion spring mechanism starts to work, and the kinetic energy of the explosion spring mechanism ejects the battery pack out of the battery swapping frame, thus separating the thermal runaway battery pack from the vehicle.

[0083] The battery quick-swap mechanism, vehicle, quick-swap method, and thermal runaway protection method of this invention are reasonably designed. They adopt a battery swapping frame structure that is compatible with battery packs of different models and sizes. The design structure is simple, facilitates battery swapping operations, and has wide applicability. At the same time, through thermal runaway detection, after thermal runaway is detected, the upper pressure bar and buckle structure are released, and the explosion spring mechanism ejects the thermal runaway battery pack, preventing further serious thermal runaway damage to the entire vehicle.

[0084] The battery swapping operation method described in this application is as follows: When the battery pack is to be swapped quickly, the quick-swap button inside the frame controls the end baffle motor and the upper pressure plate drive motor, opening the end baffle and upper pressure plate. The battery pack slides into the battery compartment through the lower slide rail of the frame, where it abuts against the explosion spring. The drive motor then closes the upper pressure bar and end baffle, locking them together to install the battery pack. To ensure reliable battery pack fixation, a mechanical pin is also included for final locking. This battery swapping frame can accommodate battery packs of different sizes by varying the thickness of the silicone pads on the upper and side baffles. When the battery needs to be removed from the swapping frame, the quick-swap button inside the frame controls the end baffle motor and the upper pressure plate drive motor, opening the end baffle and upper pressure plate. The battery pack can then be manually removed from the swapping frame, making the swapping operation simple and convenient.

[0085] A specific example of the battery thermal runaway protection method in this application is as follows: When thermal runaway occurs in the battery pack, the BMS determines that thermal runaway has occurred by judging conditions such as battery voltage, temperature, and insulation. When two or more of the following conditions are met simultaneously, the battery pack is considered to have thermal runaway: minimum single-cell voltage Vmin < 2.0V (300ms), maximum single-cell temperature Tmax > 68℃, and single-cell temperature difference > 30℃ (2000ms).

[0086] The thermal runaway signal is sent to the vehicle's VCU. The VCU then sends a command to the drive motor controller MCU. The MCU drives the end baffle motor and the upper pressure plate motor to open. At this time, the explosion spring starts to work. The kinetic energy of the explosion spring ejects the battery pack out of the battery swapping frame, thus separating the thermal runaway battery pack from the vehicle.

[0087] This system can not only separate the battery pack from the vehicle frame under high voltage conditions, but also, after the vehicle is powered off, the BMS can wake up the vehicle network by AFE self-wake-up and judging several thermal runaway trigger conditions to report thermal runaway signals, realizing 24-hour monitoring of the vehicle. It can separate the battery pack from the frame as soon as possible to avoid greater losses.

[0088] This battery thermal runaway protection method can effectively solve the problem of vehicle fire caused by battery pack thermal runaway. When the battery pack experiences thermal runaway, the BMS monitors parameters such as the minimum voltage, maximum temperature, and temperature difference of each cell. If two specified conditions are met, thermal runaway is determined. The system then sends a signal to the VCU, which instructs the MCU to drive the baffle and pressure plate motors to open. The kinetic energy of the explosion spring is then used to eject the faulty battery pack from the battery swapping frame, achieving rapid separation from the vehicle. At the same time, the system supports BMS self-wake-up via AFE after the vehicle is powered off, continuously monitoring thermal runaway conditions and waking up the vehicle network to report, achieving uninterrupted monitoring. When battery thermal runaway occurs, the system can promptly separate the thermal runaway battery pack, avoid safety risks, and reduce losses.

[0089] The above description is merely an illustration of preferred embodiments of the present invention, and the above technical features can be arbitrarily combined to form multiple embodiments of the present invention.

[0090] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the concept and technical solution of the present invention, or the direct application of the concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A battery quick change mechanism, characterized by: The battery quick-change mechanism is a battery swapping frame structure, which includes a bottom frame for carrying the battery, an upper pressing structure for pressing and positioning the battery and being able to move upward, and an end baffle that can be flipped open on the bottom frame corresponding to the outer end of the battery.

2. The battery quick change mechanism of claim 1, wherein: The upper pressing structure is an upper pressure bar, and the battery swapping frame structure is provided with an upward flipping drive structure for driving the upper pressure bar to flip upward.

3. The battery quick change mechanism of claim 2, wherein: The upward driving structure includes a flipping frame corresponding to the inner end of the battery, an upper pressure bar with its inner end located on the top of the flipping frame, and an upper pressure bar drive motor for driving the flipping frame to flip on the bottom frame.

4. The battery quick change mechanism of claim 2, wherein: The bottom frame is provided with a vertical plate corresponding to the inner end of the battery. The inner end of the upper pressure strip is hinged to the top of the vertical plate, and the outer end of the upper pressure strip is connected to a top rod. The bottom frame is provided with a lifting drive structure for lifting the top rod.

5. The battery quick change mechanism of claim 4, wherein: The lifting drive structure includes a motor base, an electric push cylinder, and a lifting slider. The electric push cylinder is located inside the motor base. The motor base has a guide hole for guiding the lifting slider. The lifting slider is located inside the guide hole and connected to the push rod of the electric push cylinder. The lifting slider has a horizontally arranged waist-shaped hole, and the push rod is located inside the waist-shaped hole.

6. The battery quick change mechanism of claim 2, wherein: A rubber pad or protrusion is provided below the upper pressure strip.

7. The battery quick change mechanism of claim 2, wherein: The lower end of the end baffle is hinged to the bottom frame via a rotating shaft, and the bottom frame is equipped with an end baffle drive motor for driving the rotating shaft to rotate.

8. The battery quick-change mechanism as described in claim 7, characterized in that: The upper end of the end baffle and the outer end of the upper pressure strip are engaged by a snap-fit ​​connection.

9. The battery quick change mechanism of claim 8, wherein: The upper outer side of the end baffle is provided with a chamfer structure, and the lower part of the outer end of the upper pressure strip is provided with a protruding clip structure that is locked onto the chamfer structure.

10. The battery quick change mechanism of claim 1, wherein: The bottom frame is provided with a side panel that is easy to pull out after the battery is unlocked. The side panel has an L-shaped structure.

11. The battery quick change mechanism of claim 1, wherein: The battery swapping frame structure is equipped with an explosion spring mechanism at the inner end of the corresponding battery to eject the battery pack in case of thermal runaway.

12. A vehicle characterized by: Includes the battery quick-swap mechanism as described in any one of claims 1 to 11, wherein two battery quick-swap mechanisms are arranged laterally opposite each other, and the outer end of the battery pack is arranged on the side corresponding to the vehicle.

13. A battery swap method for swapping a battery pack of a vehicle using the battery swap mechanism according to any one of claims 1 to 11, characterized by: Includes the following steps: The upper clamping structure and end baffle are flipped to unlock the battery pack, which is then pulled out of the battery swapping frame structure for battery swapping.

14. A battery thermal runaway protection method, characterized in that: Includes the following steps: When the battery pack experiences thermal runaway, a thermal runaway signal is sent to the vehicle's VCU unit. The VCU unit then sends a command to the motor controller, which in turn controls the end baffle drive motor and the upper pressure bar drive motor to operate. The battery pack is unlocked by opening the end baffle and upper pressure bar driven by the corresponding motors. At this time, the explosion spring mechanism starts to work, and the kinetic energy of the explosion spring mechanism ejects the battery pack out of the battery swapping frame, thus separating the thermal runaway battery pack from the vehicle.

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