AGV battery charging device

Abstract

The application relates to the technical field of AGV battery charging and replacing, and discloses an AGV battery charging and replacing device, which comprises a large battery assembly, a small battery assembly is arranged on the top of the large battery assembly, the small battery assembly is inserted into a pull-out type battery compartment of an AGV vehicle body, a quick plug-in plug is arranged on the outer side to realize power supply loop communication, directional wheels are arranged on the bottom of the large battery assembly, a hidden handle is arranged on the pull-out end, and a battery management control unit, a double-path charging pile unit, a battery identity recognition module, a multi-stage fault protection module and a wireless communication module are integrated in the large and small batteries; the double-path charging pile unit supports in-situ synchronous charging of the whole vehicle and offline independent charging of the battery; the battery management control unit is provided with four types of control algorithms; the application adopts a main and standby double-battery structure, the small battery can guarantee seamless power supply during battery replacement, operation continuity can be ensured, and charging power can be dynamically adjusted; the labor-saving pull-out structure simplifies the battery replacement operation, and the algorithm optimization can delay battery loss.

Description

Technical Field

[0001] This invention relates to the field of AGV battery charging and swapping technology, specifically to an AGV battery charging and swapping device. Background Technology

[0002] As industrial automation scenarios continue to expand and the scale of AGV cluster applications continues to grow, the requirements for power supply continuity, charging and swapping convenience, and full-cycle battery operation and maintenance management are also increasing.

[0003] Existing AGV battery systems mostly adopt a single-battery power supply architecture. Both battery swapping and charging operations require stopping vehicle operation. The power supply switching process has obvious power supply gaps and voltage fluctuations, which are difficult to adapt to the continuous production line operation rhythm. In addition, existing charging devices mostly adopt a fixed power single-channel output structure, which can only support a single charging scenario and cannot simultaneously meet the needs of vehicle charging in place and battery charging offline. Furthermore, the charging power cannot be flexibly adjusted according to the work schedule and battery status, resulting in poor adaptability of the energy replenishment rhythm to the production cycle. Furthermore, the auxiliary guidance and labor-saving design of the existing battery pull-out replacement structure are not perfect. When manually replacing batteries, the operation resistance is large and the process is cumbersome, which increases the time and labor costs of operation and maintenance. In addition, the battery management only has basic charging and discharging protection functions, and the control of battery health status is relatively rough. The full-cycle battery identification traceability mechanism and hierarchical fault protection system are not perfect. The battery degrades quickly and the electrical safety protection level is insufficient, which cannot meet the working requirements of AGV battery charging and replacement. Therefore, an AGV battery charging and replacement device is proposed. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an AGV battery charging and swapping device to solve the technical problems of intermittent power supply and low charging and swapping maintenance efficiency.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an AGV battery charging and swapping device, comprising a large battery assembly: The large battery assembly is equipped with a small battery assembly on top. The large battery assembly is inserted into the pull-out battery compartment of the AGV body. The external connection end of the pull-out battery compartment is equipped with a quick-connect plug. The large battery assembly is electrically connected to the power supply circuit of the AGV body through the quick-connect plug. The large battery module is equipped with directional wheels on both sides of its bottom, and a hidden handle is installed at the pull-out end of the large battery module. The device is equipped with a centralized battery management control unit and a dual-path charging pile unit. The large battery module and the small battery module both integrate a cell acquisition unit, a battery identification tag, and a hardware protection submodule. The battery management control unit is electrically connected to the large battery module, the small battery module, and the dual-path charging pile unit, respectively. The dual-path charging pile unit is used to charge the large battery module and the small battery module simultaneously when the AGV is in place, and to charge the large battery module offline independently after it is disassembled. The battery management control unit is electrically connected to the large battery module, the small battery module and the dual-path charging pile unit respectively. The battery management control unit has built-in dual-battery dynamic power supply scheduling, dual-path charging power intelligent allocation, battery health status assessment and thermal management closed-loop control algorithm. The battery identification module is used to identify the identity of large battery components and match their full-cycle operation and maintenance records. The multi-level fault protection module is used to collect battery electrical parameters and perform graded power-off protection. The wireless communication module is used to connect to the plant dispatching platform to realize remote management and cluster charging scheduling.

[0006] Preferably, the dual-battery dynamic power supply scheduling algorithm built into the battery management control unit is used to collect task parameters such as the current load, travel path length, and working conditions of the AGV, and simultaneously read the real-time remaining power data of the large battery component. It calculates the power shortage prediction result through a range threshold model. Before the large battery component's power drops to a preset warning line, it controls the small battery component to smoothly connect to the power supply circuit. When it detects that the large battery component has been pulled out of the pull-out battery compartment and detached from the AGV body, the dual-battery dynamic power supply scheduling algorithm immediately controls the small battery component to switch to independent power supply mode, ensuring uninterrupted AGV operation during the offline charging of the large battery component. Furthermore, the dual-battery dynamic power supply scheduling algorithm incorporates load grading logic, which corresponds to the independent power supply mode of the small battery component in light-load standby scenarios and the parallel power replenishment mode of the dual batteries in heavy-load operation scenarios. This algorithm can predict power shortages in advance, achieving smooth switching between the two batteries without fluctuations. By matching different working conditions with power supply modes based on load grading logic, it avoids downtime during large battery replacement, ensuring continuous and stable power supply for various light and heavy-load operations of the AGV.

[0007] Preferably, the dual-path charging power intelligent allocation algorithm built into the battery management control unit optimizes charging efficiency, battery life, and electricity cost. It collects the remaining power, health status, and temperature parameters of the large and small battery modules in real time, and dynamically adjusts the output power of the two charging circuits of the dual-path charging pile unit based on the departure time data of the AGV's next task. The dual-path charging power intelligent allocation algorithm incorporates charging strategies corresponding to emergency dispatch scenarios and long-term standby scenarios, and also incorporates peak-valley electricity price scheduling logic. It adjusts the charging execution period and charging power level according to the electricity price period. This algorithm can dynamically allocate the charging power of the two paths from multiple dimensions, adapting to different scenarios of emergency vehicle dispatch and long-term standby. It adjusts the charging schedule based on the electricity price period, taking into account the vehicle's recharge speed, battery life, and factory electricity consumption.

[0008] Preferably, the battery health status assessment algorithm built into the battery management control unit is used to collect historical charge and discharge data, operating temperature curves, and current surge records of large and small battery modules. It then uses an equivalent circuit model combined with machine learning algorithms to calculate the battery's capacity decay rate and internal resistance change trend online, outputting a corresponding health status value. This battery health status assessment algorithm establishes a dedicated decay profile for each large battery module and optimizes the charge and discharge cutoff voltage parameters based on the decay data in the profile. Simultaneously, it limits the peak discharge current. This algorithm can analyze long-term battery operating data in real time, accurately capture battery decay changes, establish an independent management profile for each battery, and adjust charge and discharge control parameters accordingly to mitigate aging losses caused by long-term battery use.

[0009] Preferably, the thermal management closed-loop control algorithm built into the battery management control unit is used to collect temperature data at multiple locations within the battery pack in real time. Combined with the current ambient temperature and the charging and discharging conditions of the battery, it dynamically adjusts the working state of the heat dissipation circuit and the heating circuit. When the battery temperature reaches a preset high temperature threshold during charging, the charging current is reduced and the heat dissipation circuit is activated. Before starting the charging process in a low-temperature environment, the heating circuit is controlled to perform a preheating program. This algorithm can sense the temperature changes across the entire battery in real time and adaptively adjust the hot and cold circuits according to the environment and working state. It reduces the current for heat dissipation during high-temperature charging and completes preheating before low-temperature charging, ensuring that the battery is always within the appropriate charging and discharging temperature range.

[0010] Preferably, the battery identification module includes an identification tag set on each large battery assembly, and identification and reading units respectively set inside the AGV battery compartment and at the end of the dual-path charging pile unit. When a large battery assembly is loaded into the AGV battery compartment or connected to the dual-path charging pile unit, the identification and reading unit automatically reads the identification tag of the corresponding large battery assembly and matches it with the file data of the battery's charging and discharging history, health status and fault records. This module can automatically identify the unique identification information of each large battery, quickly retrieve the full cycle operation file of the corresponding battery, distinguish batteries in different states of wear, and avoid the management confusion caused by mixing batteries with different operating conditions and different aging degrees.

[0011] Preferably, the multi-level fault protection module collects parameters such as voltage, current, cell temperature, and insulation resistance of the battery circuit in real time. The module also incorporates a three-level protection mechanism: early warning, current limiting, and disconnection. These three mechanisms correspond to different levels of abnormal parameter thresholds. When a minor abnormal threshold is triggered, an early warning signal is pushed and the circuit's operating power is reduced. When a moderate abnormal threshold is triggered, the power supply circuit to unnecessary loads is disconnected. When a severe abnormal threshold is triggered, the main power supply circuit is immediately disconnected. The multi-level fault protection module is equipped with an independent hardware protection circuit, which forms a redundant configuration with the main control protection logic of the battery management control unit. This module responds to various electrical anomalies in a layered manner, performing power regulation, load disconnection, and main circuit power-off operations in stages. Combined with the independent hardware protection circuit, it forms dual protection, comprehensively avoiding various safety hazards caused by battery circuit anomalies.

[0012] Preferably, the wireless communication module adopts an industrial-grade wireless communication unit. The wireless communication module periodically reports operational data such as remaining battery power, health status, charging progress, and fault information to the plant dispatching platform. At the same time, the wireless communication module is used to receive reverse control commands issued by the plant dispatching platform and execute charging start / stop, power limiting, and battery switching operations accordingly. This communication unit establishes a data communication channel between the battery device and the plant dispatching platform, synchronizes various battery operation information in real time, and synchronously receives control commands issued by the platform, realizing remote unified scheduling and management of battery charging operations of multiple AGVs.

[0013] Preferably, the directional wheels are symmetrically arranged on both sides of the bottom along the length of the pull-out battery compartment, and the wheel surface of the directional wheels protrudes from the bottom surface of the pull-out battery compartment. The hidden handle is embedded in the end face groove of the pull-out end of the large battery assembly. The symmetrically arranged directional wheels reduce the resistance of pulling out the battery by rolling cooperation. The hidden handle is stored in the end face groove, which simplifies the operation of manually pulling out and replacing the battery, does not take up extra space, and keeps the overall structure of the battery assembly neat.

[0014] Preferably, the quick-connect plug consists of two parts: a male end and a female end. The male end of the quick-connect plug is fixedly installed on the connection end face of the large battery assembly, and the female end of the quick-connect plug is fixedly installed on the inner end face of the pull-out battery compartment. The contact terminals of the male and female ends are arranged accordingly. The plug is equipped with matching male and female ends and corresponding conductive terminals are arranged. When the large battery is pushed into the compartment, the connection can be automatically completed, simplifying the electrical connection operation. The terminal alignment structure ensures a stable and reliable connection between the battery and the vehicle body power supply circuit.

[0015] Compared with the prior art, the present invention provides an AGV battery charging and swapping device, which has the following beneficial effects: This AGV battery charging and swapping device, through its design combining a dual-battery architecture with large and small battery modules and a battery management control unit, effectively ensures the continuity and stability of AGV operations. Simultaneously, through a dual-battery dynamic power supply scheduling algorithm, the backup battery can smoothly take over power supply when the main battery is removed, replaced, or has insufficient power, eliminating operational interruptions during battery swapping and charging. This ensures AGV online operation at all times and is suitable for both in-situ automatic charging and offline independent battery charging scenarios. Combined with dynamic adjustment capabilities for charging power, it can flexibly adjust charging strategies according to work schedules to meet the energy replenishment needs under different production rhythms. Furthermore, the pull-out battery compartment combined with directional wheels and a concealed handle simplifies the battery replacement process and reduces manual labor intensity. Simultaneously, the accompanying battery health assessment and thermal management closed-loop control algorithm optimizes the charging and discharging process based on actual battery conditions, slowing down battery degradation and extending overall battery life. The added battery identification module and multi-level fault protection module standardize the entire battery lifecycle operation and maintenance management, strengthen electrical safety protection during charging and discharging, and achieve globally optimized allocation of charging resources. Attached Figure Description

[0016] Figure 1 This is a side view of the structure of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention from a bottom view; Figure 3 This is a front view structural diagram of the present invention.

[0017] In the picture: 1. Pull-out battery compartment; 2. Small battery assembly; 3. Quick-connect plug; 4. Directional wheels; 5. Concealed handle. Detailed Implementation

[0018] This invention provides a technical solution: an AGV battery charging and swapping device, comprising a pull-out battery compartment 1, a small battery assembly 2, a quick-connect plug 3, directional wheels 4, and a concealed handle 5. Please see Figure 1 The large battery assembly is topped with a small battery assembly 2. The large battery assembly is inserted into the pull-out battery compartment 1 of the AGV body. Please refer to [link / reference]. Figure 2 The external connection end of the pull-out battery compartment 1 is equipped with a quick-plug plug 3, and the large battery assembly is electrically connected to the power supply circuit of the AGV vehicle body through the quick-plug plug 3. Please see Figure 3The large battery module is equipped with directional wheels 4 on both sides of its bottom. The pull-out end of the large battery module is equipped with a hidden handle 5. The device is equipped with a centralized battery management control unit and a dual-path charging pile unit. The large battery module and the small battery module 2 are both integrated with a cell acquisition unit, a battery identification tag and a hardware protection sub-module. The battery management control unit is electrically connected to the large battery module, the small battery module (2) and the dual-path charging pile unit respectively, so that the large battery module and the small battery module 2 are unified into a single centralized control architecture. That is, the battery management control unit is the core control center of the whole device, integrated in the control cavity of the pull-out battery compartment, and uniformly collects the status of the two batteries, performs power supply scheduling and charging power allocation. The dual-path charging pile unit is an independent charging interface unit, providing two independent charging circuits. The battery body only integrates cell parameter acquisition, identification tag and underlying hardware protection sub-module. The charging pile unit is used to charge the large battery module and the small battery module 2 simultaneously when the AGV is in place, and to charge the large battery module offline independently after it is disassembled. The battery management control unit is electrically connected to the large battery module, the small battery module 2 and the dual-path charging pile unit respectively. The battery management control unit has built-in dual-battery dynamic power supply scheduling, dual-path charging power intelligent allocation, battery health status assessment and thermal management closed-loop control algorithm. The fixed compartment of the pull-out battery compartment 1 is a rectangular shell extending along the pull-out direction. The rear side, which is fixedly connected to the AGV body, is the fixed closed end, and the front side facing the operation side is the pull-out open end. The inner cavity of the fixed closed end is divided into two parts by a vertical partition. The front part is the battery receiving cavity, which is used to accommodate the large battery module and the small battery module 2 and provide pull-out guidance. The rear part is an independent sealed control installation cavity. The centralized battery management control unit is fastened to the inner wall of the control installation cavity by bolts.

[0019] The centralized battery management control unit integrates a core main control module, a multi-channel cell acquisition interface unit, a dual-channel charging control interface unit, a load power supply switching execution unit, a vehicle operating condition interaction interface unit, an identity recognition and matching unit, a local data storage unit, and an industrial communication unit. The core control module adopts an automotive-grade microcontroller with real-time computing capabilities. It incorporates four core algorithm programs: dual-battery dynamic power supply scheduling, dual-path intelligent charging power allocation, battery health status assessment, and thermal management closed-loop control. It also carries the logical judgment function for fault protection and is the core of the entire device's computing and decision-making. All control commands are generated and issued by this module. The multi-channel cell acquisition interface unit is configured with two independent acquisition channels, which are connected to the cell acquisition sub-units inside the large and small battery modules respectively through the signal terminals of the quick-plug connector. It collects low-level operating parameters such as individual cell voltage, total voltage, charging and discharging current, multi-point cell temperature, and circuit insulation resistance of each battery in real time at a fixed sampling period. After signal filtering, the data is transmitted to the core control module to provide raw data support for various algorithm calculations.

[0020] The dual-channel charging control interface unit is electrically connected to the two independent charging circuits of the dual-channel charging pile unit, and has functions such as power regulation signal output, charging on / off control, and charging status feedback acquisition. It can dynamically adjust the output current and voltage of the two charging circuits according to the instructions of the core main control module, and simultaneously collect the working status of the charging circuits in real time and send it back to the main control module. The load power supply switching execution unit is connected to the AGV vehicle load power supply bus. It is internally equipped with a large battery main circuit contactor, a small battery backup circuit contactor, a parallel voltage regulating buffer circuit, and a current detection device. It is responsible for executing the power supply switching instructions issued by the core main control module, realizing smooth grid connection of the two batteries, load transfer, and independent power supply switching, and suppressing voltage fluctuations and current surges during the switching process. The vehicle operating condition interaction interface unit establishes bidirectional communication with the AGV vehicle controller through the industrial CAN bus, and obtains real-time vehicle operation data such as the current load level, preset driving path length, working condition identification, and next task departure time. At the same time, it reports information such as battery remaining power, health status, power supply warning, and fault alarm to the vehicle controller, realizing the coordinated linkage between the battery system and the vehicle operation.

[0021] The identification and matching unit connects to the identification and reading units inside the pull-out battery compartment and the offline charging station. When a large battery module is installed in the battery compartment or connected to the offline charging station, it automatically reads the identification tag code on the battery surface and retrieves the corresponding full-cycle operation and maintenance file of the battery from the local data storage unit. This file includes charging and discharging history, attenuation data, fault records, calibration parameters, etc., enabling full life-cycle identification traceability and differentiated management of the battery. The local data storage unit uses non-volatile storage media to locally store the identification files, historical operating data, attenuation trend models, control parameter thresholds, and fault logs of all registered batteries. It also caches external data such as charging schedules, peak and off-peak electricity price schedules, and cluster scheduling strategies issued by the plant dispatching platform, ensuring that the control logic can still operate normally in the event of a network outage. The industrial communication unit uses an industrial-grade wireless LAN communication module to connect to the internal industrial control network of the plant and establish a two-way data interaction channel with the plant dispatching platform. It periodically reports data such as battery operating status, charging progress, and fault information, while receiving remote control commands, cluster charging scheduling strategies, and model parameter update packages issued by the dispatching platform, enabling global collaborative management of multiple AGV battery systems.

[0022] The battery identification module identifies the large battery component and matches it with its full-cycle operation and maintenance file. The multi-level fault protection module collects battery electrical parameters and executes graded power-off protection. The wireless communication module connects to the factory dispatch platform to achieve remote control and cluster charging scheduling. The dual-battery dynamic power supply scheduling algorithm built into the battery management control unit collects task parameters such as the AGV's current load, travel path length, and working conditions, and synchronously reads the real-time remaining power data of the large battery component. It calculates the power shortage prediction result through the endurance threshold model. Before the large battery component's power drops to the preset warning line, it controls the small battery component to smoothly connect to the power supply circuit. When it detects that the large battery component is pulled out of the pull-out battery compartment 1 and detached from the AGV body, the dual-battery dynamic power supply scheduling algorithm immediately controls the small battery component 2 to switch to independent power supply mode, so that the AGV operation is uninterrupted during the offline charging of the large battery component. The dual-battery dynamic power supply scheduling algorithm has built-in load classification logic, which corresponds to the independent power supply mode of the small battery component 2 in the light load standby scenario and the dual-battery parallel energy replenishment mode in the heavy load operation scenario.

[0023] The battery management control unit incorporates a dual-path intelligent charging power allocation algorithm. This algorithm optimizes charging efficiency, battery lifespan, and electricity costs by collecting real-time data on the remaining charge, health status, and temperature parameters of both the large and small battery modules. It also dynamically adjusts the output power of the two charging circuits based on the AGV's next task departure time. The algorithm includes charging strategies for emergency deployment and long standby scenarios, along with peak-valley electricity pricing logic to adjust charging execution periods and power levels according to electricity price periods. The battery management control unit also incorporates a battery health status assessment algorithm. This algorithm collects historical charge / discharge data, operating temperature curves, and current surge records from both the large and small battery modules. Using an equivalent circuit model combined with machine learning algorithms, it estimates the battery's capacity decay rate and internal resistance trend online, outputting corresponding health status values. The algorithm creates a dedicated decay profile for each large battery module and optimizes the charge / discharge cutoff voltage parameters based on the decay data within the profile, while also limiting the peak discharge current.

[0024] The battery management control unit incorporates a closed-loop thermal management algorithm to collect temperature data from multiple locations within the battery pack in real time. Combining this data with the current ambient temperature and the battery's charging / discharging conditions, it dynamically adjusts the operation of the heat dissipation and heating circuits. During charging, when the battery temperature reaches a preset high-temperature threshold, it correspondingly reduces the charging current and activates the heat dissipation circuit. Before initiating the charging process in low-temperature environments, it controls the heating circuit to perform a preheating procedure. The battery identification module includes an identification tag on each large battery assembly, and identification and reading units located inside the AGV battery compartment and at the end of the dual-path charging pile unit. When a large battery assembly is loaded into the AGV battery compartment or connected to the dual-path charging pile unit, the identification and reading units automatically read the identification tag of the corresponding large battery assembly and match it with the battery's charging / discharging history, health status, and fault record data.

[0025] The multi-level fault protection module collects parameters such as voltage, current, cell temperature, and insulation resistance of the battery circuit in real time. It also incorporates a three-level protection mechanism: early warning, current limiting, and disconnection. Each level corresponds to a different threshold for abnormal parameters. Triggering a minor abnormal threshold sends an early warning signal and reduces the circuit's operating power. Triggering a moderate abnormal threshold disconnects the power supply to unnecessary loads. Triggering a severe abnormal threshold immediately disconnects the main power supply circuit. The multi-level fault protection module has an independent hardware protection circuit, which forms a redundant configuration with the main control protection logic of the battery management control unit. The wireless communication module uses an industrial-grade wireless communication unit. It periodically reports operational data such as remaining battery power, health status, charging progress, and fault information to the plant dispatch platform. Simultaneously, the wireless communication module receives reverse control commands from the plant dispatch platform, corresponding to execute charging start / stop, power limiting, and battery switching operations.

[0026] The specific execution process of the dual-battery dynamic power supply scheduling algorithm is as follows: The battery management control unit reads the terminal voltage, real-time discharge current, and remaining power parameters output by the fuel gauge of the large battery module according to a fixed sampling period. At the same time, it obtains the current load level, the preset total length of the driving path, and the working condition identifier from the AGV vehicle controller through the internal bus. The above parameters are input into the endurance threshold model to complete the calculation of the remaining endurance time. When the remaining endurance time drops to the preset switching warning threshold, the control unit sends a grid connection command to the voltage regulation circuit of the small battery module, gradually raising the output voltage of the small battery module to be equal to the output voltage of the large battery module. Then, the contactor of the small battery circuit is closed to complete the parallel transition of the dual batteries. After the large battery module is disconnected or removed from the battery compartment, the small battery module independently undertakes the entire load. The load classification logic identifies the load level signal output by the AGV vehicle controller and switches the power supply mode of independent power supply of the small battery or parallel power supply of the dual batteries accordingly.

[0027] The specific allocation logic of the dual-path charging power intelligent allocation algorithm is as follows: The battery management control unit pre-configures corresponding weight coefficients for the three optimization objectives of charging efficiency, battery life, and electricity cost, and collects data on the remaining power, maximum cell temperature, and health status level of the two batteries in real time. At the same time, it retrieves the next task departure time issued by the AGV scheduling system and the peak and off-peak electricity price schedule of the factory area. When an emergency dispatch instruction is received, the weight ratio of the charging circuit of the large battery component is increased to charge the large battery component at full power, while the small battery component circuit uses low-power trickle charging. When it is detected that the AGV is in a long standby state, the charging power is gradually increased by step current. The charging power is automatically increased during the off-peak electricity price period and the charging power is reduced or unnecessary charging is suspended during the peak electricity price period.

[0028] The specific calculation process of the battery health status assessment algorithm is as follows: The battery management control unit continuously stores the charge and discharge current curves, terminal voltage change data, cell temperature extreme values, and surge current records of each battery. The above historical data is input into the first-order RC equivalent circuit model to fit and calculate the changes in the battery's ohmic internal resistance and polarization internal resistance. The machine learning model is combined to predict the changes in internal resistance and capacity decay trends, and output the corresponding battery health status level. An independent decay profile is generated for each large battery module. When the health status drops to a preset level, the charge and discharge cutoff voltage threshold and the maximum allowable discharge current value are lowered accordingly. The machine learning model uses the full life cycle operation data of the same model of battery as training samples and can receive updated model parameters from the cloud through the wireless communication module.

[0029] The specific control method of the thermal management closed-loop control algorithm is as follows: multiple temperature sampling points are set inside the battery pack along the cell arrangement direction to collect temperature data of the cell surface, busbar, and air intake position of the battery pack; the control unit adopts proportional-integral-derivative adjustment logic to adjust the cooling fan speed and heating film power supply according to the difference between the current battery temperature and the target temperature range; when the highest temperature of the cell exceeds the high temperature threshold during charging, the charging current is gradually reduced proportionally, and the cooling circuit is started to run at full speed; when the ambient temperature is lower than the low temperature threshold, the heating circuit is first turned on to preheat the cell, and the charging process is started after the overall temperature of the cell enters the appropriate range.

[0030] The specific hardware implementation of each functional module is as follows: The battery identification module uses passive RFID tags attached to the side of the outer shell of each large battery module. The identification and reading units are respectively installed on the inner wall of the pull-out battery compartment 1 and the inner side of the battery access port of the charging pile. When the battery is installed or connected, the reading unit automatically senses the unique identification code stored in the tag and calls the corresponding battery file data stored locally. The three-level protection logic of the multi-level fault protection module is implemented by the software program of the battery management control unit. The independent hardware protection circuit consists of a dedicated analog protection chip and a hardware fuse. The hardware circuit directly collects the circuit current and voltage parameters. In case of abnormality, it directly triggers power-off and is not affected by the operating status of the main control unit. The wireless communication module uses an industrial wireless local area network communication unit to access the internal industrial network of the factory. It uses a standard industrial communication protocol to interact with the scheduling platform. The data upload cycle can be configured according to scheduling requirements.

[0031] The directional wheels 4 are symmetrically arranged on both sides of the bottom along the length of the pull-out battery compartment 1. The wheel surface of the directional wheels 4 protrudes from the bottom surface of the pull-out battery compartment 1. The hidden handle 5 is embedded in the end face groove of the pull-out end of the large battery assembly. The quick-plug plug 3 is divided into two parts: a male end and a female end. The male end of the quick-plug plug 3 is fixedly installed on the connection end face of the large battery assembly, and the female end of the quick-plug plug 3 is fixedly installed on the inner end face of the pull-out battery compartment 1. The contact terminals of the male end and the female end are arranged correspondingly.

[0032] This solution employs a dual-battery architecture combining large and small battery modules with a battery management control unit, effectively ensuring the continuity and stability of AGV operations. Through a dynamic dual-battery power supply scheduling algorithm, the backup battery can smoothly take over power when the main battery is removed, replaced, or runs low, eliminating operational interruptions during battery swapping and charging. This ensures AGVs operate online 24 / 7, adapting to both in-situ automatic charging and offline independent battery charging scenarios. Combined with dynamic charging power adjustment capabilities, charging strategies can be flexibly adjusted according to work schedules to meet energy replenishment needs under different production rhythms. Furthermore, the pull-out battery compartment 1, along with directional wheels and a concealed handle, simplifies battery replacement procedures and reduces manual labor intensity. The accompanying battery health assessment and thermal management closed-loop control algorithm optimizes the charging and discharging process based on actual battery conditions, slowing battery degradation and extending overall battery life. The added battery identification module and multi-level fault protection module standardize battery lifecycle maintenance management, strengthen electrical safety protection during charging and discharging, and achieve globally optimized allocation of charging resources.

Claims

1. An AGV battery charging and swapping device, comprising a pull-out battery compartment (1), characterized in that: The pull-out battery compartment (1) integrates a large battery assembly inside, and a small battery assembly (2) is installed on the top of the large battery assembly. The external connection end of the pull-out battery compartment is equipped with a quick-plug plug (3). The large battery assembly is electrically connected to the power supply circuit of the AGV vehicle body through the quick-plug plug (3). The large battery module is equipped with directional wheels (4) on both sides of its bottom. The pull-out end of the large battery module is equipped with a hidden handle (5). The device is equipped with a centralized battery management control unit and a dual-path charging pile unit. The large battery module and the small battery module (2) are both equipped with a cell acquisition unit, a battery identification tag and a hardware protection sub-module. The centralized battery management control unit is electrically connected to the large battery module, the small battery module (2) and the dual-path charging pile unit respectively. The dual-path charging pile unit is used to charge the large battery component and the small battery component (2) simultaneously when the AGV is in place, and to charge the large battery component offline independently after it is disassembled. The battery management control unit is electrically connected to the large battery component, the small battery component (2) and the dual-path charging pile unit respectively. The battery management control unit has built-in dual-battery dynamic power supply scheduling, dual-path charging power intelligent allocation, battery health status assessment and thermal management closed-loop control algorithm. The battery identification module is used to identify the identity of large battery components and match their full-cycle operation and maintenance records. The multi-level fault protection module is used to collect battery electrical parameters and perform graded power-off protection. The wireless communication module is used to connect to the plant dispatching platform to realize remote management and cluster charging scheduling.

2. The AGV battery charging and swapping device according to claim 1, characterized in that: The dual-battery dynamic power supply scheduling algorithm built into the battery management control unit is used to collect the task parameters of the AGV's current load, travel path length and working conditions, and synchronously read the real-time remaining power data of the large battery component. The power supply gap prediction result is obtained by calculating the endurance threshold model. Before the power of the large battery component drops to the preset warning line, the small battery component is controlled to smoothly connect to the power supply circuit. When the large battery component is detected to be pulled out from the pull-out battery compartment (1) and detached from the AGV body, the dual-battery dynamic power supply scheduling algorithm immediately controls the small battery component (2) to switch to independent power supply state, so that the AGV operation is uninterrupted during the offline charging of the large battery component. The dual-battery dynamic power supply scheduling algorithm has built-in load classification logic. The load classification logic corresponds to the independent power supply mode of the small battery component (2) in the light load standby scenario and the dual-battery parallel energy replenishment mode in the heavy load operation scenario.

3. The AGV battery charging and swapping device according to claim 1, characterized in that: The dual-path charging power intelligent allocation algorithm built into the battery management control unit takes charging efficiency, battery life and electricity cost as optimization goals, collects the remaining power, health status and temperature parameters of the large battery component and the small battery component (2) in real time, and dynamically adjusts the output power of the two charging circuits of the dual-path charging pile unit in combination with the departure time data of the AGV for the next task. The dual-path charging power intelligent allocation algorithm has built-in charging strategies corresponding to emergency departure scenarios and long standby scenarios, and superimposes peak and valley electricity price scheduling logic to adjust the charging execution period and charging power level according to the electricity price period.

4. The AGV battery charging and swapping device according to claim 1, characterized in that: The battery health status assessment algorithm built into the battery management control unit is used to collect historical charge and discharge data, operating temperature curves and current impact records of large battery modules and small battery modules (2), and to perform calculations by combining equivalent circuit models with machine learning algorithms to estimate the battery capacity decay rate and internal resistance change trend online, and output the corresponding health status value. The battery health status assessment algorithm establishes a dedicated decay file for each large battery module, and optimizes the charge and discharge cutoff voltage parameters according to the decay data in the file, while limiting the peak discharge current accordingly.

5. The AGV battery charging and swapping device according to claim 1, characterized in that: The thermal management closed-loop control algorithm built into the battery management control unit is used to collect temperature data at multiple locations within the battery pack in real time. Combined with the current ambient temperature and the charging and discharging conditions of the battery, it dynamically adjusts the working state of the heat dissipation circuit and the heating circuit. When the battery temperature reaches a preset high temperature threshold during charging, the charging current is reduced and the heat dissipation circuit is activated. Before starting the charging process in a low-temperature environment, the heating circuit is controlled to perform a preheating program.

6. The AGV battery charging and swapping device according to claim 1, characterized in that: The battery identification module includes an identification tag set on each large battery component, and identification and reading units set inside the AGV battery compartment and at the end of the dual-path charging pile unit, respectively. When a large battery component is loaded into the AGV battery compartment or connected to the dual-path charging pile unit, the identification and reading unit automatically reads the identification tag of the corresponding large battery component and matches it with the file data of the battery's charging and discharging history, health status and fault records.

7. The AGV battery charging and swapping device according to claim 1, characterized in that: The multi-level fault protection module collects parameters such as voltage, current, cell temperature, and insulation resistance of the battery circuit in real time. The multi-level fault protection module has a built-in three-level protection mechanism of early warning, current limiting, and disconnection. The three-level protection mechanism corresponds to different levels of abnormal parameter thresholds. When a minor abnormal threshold is triggered, an early warning signal is pushed and the circuit operating power is reduced. When a moderate abnormal threshold is triggered, the power supply circuit of unnecessary loads is disconnected. When a severe abnormal threshold is triggered, the main power supply circuit is immediately disconnected. The multi-level fault protection module is configured with an independent hardware protection circuit, which forms a redundant configuration with the main control protection logic of the battery management control unit.

8. The AGV battery charging and swapping device according to claim 1, characterized in that: The wireless communication module adopts an industrial-grade wireless communication unit. The wireless communication module periodically reports the remaining battery power, health status, charging progress and fault information to the plant dispatch platform. At the same time, the wireless communication module is used to receive reverse control commands issued by the plant dispatch platform and execute charging start / stop, power limiting and battery switching operations accordingly.

9. The AGV battery charging and swapping device according to claim 1, characterized in that: The directional wheels (4) are symmetrically arranged on both sides of the bottom along the length of the pull-out battery compartment (1). The wheel surface of the directional wheels (4) protrudes from the bottom surface of the pull-out battery compartment (1). The hidden handle (5) is embedded in the end face groove of the pull-out end of the large battery assembly.

10. An AGV battery charging and swapping device according to claim 1, characterized in that: The quick-plug plug (3) is divided into two parts: a male end and a female end. The male end of the quick-plug plug (3) is fixedly installed on the connection end face of the large battery assembly, and the female end of the quick-plug plug (3) is fixedly installed on the inner end face of the pull-out battery compartment (1). The contact terminals of the male end and the female end are arranged accordingly.

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