Battery replacement system and battery rack assembly of electric vehicle

Abstract

The utility model relates to a battery rack assembly of an electric vehicle battery replacement system, a battery rack is of a multilayer structure, and the battery rack assembly comprises a hydroelectric connector edge distance mechanism, a hydroelectric connector up-and-down sliding seat and a plurality of guide rail systems which are arranged on a battery rack upright post. The hydroelectric connector edge distance mechanism is matched with the driving mechanism through a sliding block and a guide rail, so that the hydroelectric connector can be adjusted between different distances to adapt to charging ports of batteries of different specifications. And each layer of the battery rack is provided with a locking and unlocking mechanism, and is provided with an electric cylinder and a guide rail to realize multi-directional sliding and locking of a lock head, so that the stable positioning of the battery is ensured. The battery rack system solves the technical problems that an existing battery rack system lacks compatibility with batteries of different sizes, and the batteries are inaccurate in positioning.

Description

Technical Field

[0001] The present application belongs to the technical field of electric vehicle battery replacement, and in particular relates to an electric vehicle battery replacement system and a battery rack assembly. Background Art

[0002] With the rapid development of the new energy vehicle industry in recent years, battery swapping—a new and faster way to replenish energy—has emerged. Current battery rack designs typically only accommodate a single battery size. While this design meets the storage and charging needs of a specific battery type, it exhibits significant limitations when multiple battery types coexist. Specifically, existing battery racks have the following shortcomings:

[0003] Lack of diversity and compatibility: Existing battery racks are generally designed for batteries of specific sizes and cannot adapt to batteries of different sizes. As a result, in the case of multiple battery specifications, multiple independent battery racks are required, which takes up more space and increases equipment and management costs.

[0004] Inaccurate positioning: In existing designs, battery placement often relies on simple physical structures that cannot accurately position the battery, which may cause the battery to shift during charging, thereby affecting charging efficiency and safety. Utility Model Content

[0005] In response to the deficiencies in the related art, the present invention provides an electric vehicle battery replacement system, which solves the technical problems in the prior art that the battery rack is not compatible with batteries of different sizes and has inaccurate positioning.

[0006] In one possible embodiment, a battery rack assembly of an electric vehicle battery replacement system is provided, comprising: a battery rack having a multi-layer structure; a water-electricity connector margin mechanism corresponding to a battery charging port installed between or on the battery rack layers, the water-electricity connector margin mechanism being installed on a battery rack column; the water-electricity connector margin mechanism comprising: a guide rail V installed on the battery rack column, a slider III installed on the guide rail V, a guide rail VI installed on the slider III through an upper and lower slide seat of the water-electricity connector, the guide rail VI being horizontally arranged, and the water-electricity connector being installed on the guide rail VI through the slider IV; a driving mechanism driving the upper and lower slide seat of the water-electricity connector or the slider III to slide up and down along the guide rail V; the slider III being connected to a horizontally arranged cam positioning member, the other end of the cam positioning member being placed in a displacement groove of a displacement column of the water-electricity connector through a pin shaft, and the displacement groove comprising two sections of communication. The spacing between the two connected grooves and the guide rail V is different, and the different spacings at both ends correspond to the charging ports of two batteries of different sizes; the locking and unlocking mechanism is arranged on the battery tray, and the battery tray is arranged on each layer of the battery rack; the battery tray includes a first layer plate and a second layer rack, and the first layer plate is installed above the second layer rack; the locking and unlocking mechanism includes a Y-axis lock and an XY-axis lock passing through the first layer plate; the back of the first layer plate is provided with an electric cylinder III, a guide rail III, an electric cylinder IV and a guide rail IV, the output shaft of the electric cylinder IV is connected to the XY-axis lock, the XY-axis lock is connected to the guide rail IV and can slide along the guide rail IV under the push of the electric cylinder IV; the back of the first layer plate is provided with an electric cylinder VIII, a guide rail VIII and a Y-axis push plate, the Y-axis lock is connected to the guide rail VIII through the Y-axis push plate, the output shaft of the electric cylinder VIII is connected to the Y-axis push plate and can push the Y-axis push plate and the connected Y-axis lock to slide along the guide rail VIII.

[0007] In a possible embodiment, it also includes multiple battery positioning devices, and a battery positioning device and a battery pad are set on each layer of the battery rack; the battery positioning device includes a large battery positioning axis and a small battery positioning axis, and the large battery positioning axis and the small battery positioning axis are installed on the battery rack and are respectively adapted to large batteries and small batteries of different sizes or specifications.

[0008] In a possible implementation, a battery pad is installed on the battery rack and is correspondingly arranged to the battery positioning device to support the battery.

[0009] In a possible embodiment, the water-electricity joint margin mechanism also includes: a proximity switch I, installed on the column of the battery rack; a sensor plate I, installed on the upper and lower sliding seats of the water-electricity joint; when the sensor plate I slides up and down along the guide rail V with the upper and lower sliding seats of the water-electricity joint until it contacts the proximity switch I, the proximity switch I is triggered and sends a signal to the control system.

[0010] In a possible implementation, the water and electricity connectors correspond to charging ports of the large battery or the small battery.

[0011] In a possible embodiment, the locking and unlocking mechanism also includes a Z-direction lock head passing through a layer of plate; wherein the Z-direction lock head is installed on an I-shaped Z-direction lifting plate on the back of a layer of plate, and an electric cylinder V is installed on the back of a layer of plate through an electric cylinder mounting seat, and the output shaft of the electric cylinder V is connected to the Z-direction lifting plate, driving the Z-direction lifting plate and the Z-direction lock head thereon to move up and down in a direction perpendicular to the plane of the layer of plate.

[0012] In one possible embodiment, a battery replacement system for an electric vehicle is provided, comprising a battery rack assembly and also comprising: a palletizer, which is arranged corresponding to the battery rack and comprises: a palletizer lifting frame and an adjustment frame, a supporting fork, an electric cylinder I, a guide rail VII and a supporting fork telescopic motor reducer assembly installed on the palletizer lifting frame; two supporting forks are provided, the two supporting forks are installed on the adjusting frame, and the adjusting frame is installed on the palletizer lifting frame through the guide rail VII; the supporting fork telescopic motor reducer assembly is installed on the adjusting frame, and is used to drive the supporting forks to extend and retract, the push rod of the electric cylinder I is connected to the adjusting frame, driving the adjusting frame to move horizontally to adjust the position of the two supporting forks; the electric cylinder I is installed on the palletizer lifting frame through the electric cylinder mounting seat; the push rod of the electric cylinder I is connected to the adjusting frame through the push rod connecting block.

[0013] In a possible embodiment, the palletizer further includes a palletizer bracket, a palletizer lifting frame is installed on the palletizer bracket by a palletizer lifting mechanism, and the palletizer lifting mechanism drives the palletizer lifting frame to move up and down along the palletizer bracket; it also includes a fall arrester, which is installed on the palletizer lifting frame through an fall arrester mounting base; the anti-fall guide rail is installed on the column of the palletizer bracket and extends along the column in the direction of movement of the palletizer lifting frame; a gap is provided in the middle of the fall arrester, and the anti-fall guide rail is placed in the gap of the fall arrester. When the palletizer lifting frame reaches the set position below, the gap clamps the anti-fall guide rail to prevent the palletizer lifting frame from falling.

[0014] Based on the above technical solution, the battery rack assembly of the electric vehicle battery replacement system of the present invention has the following beneficial effects:

[0015] The multi-layer battery rack and the corresponding large battery positioning axes and small battery positioning axes can adapt to the positioning and support requirements of batteries of different specifications and improve the versatility of the system.

[0016] The setting of the unlocking mechanism realizes stable locking and unlocking operations for batteries of different specifications through the coordinated movement of the multi-directional lock head, ensuring the safety of the battery during replacement and use.

[0017] The application of the water-electricity joint margin mechanism enables the system to automatically adapt to the charging port position of batteries of different specifications, thereby meeting the charging needs of different models of batteries and improving the system's automation level and flexibility of use. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0019] Figure 1 This is a schematic diagram of the placement of two types of batteries in the battery rack solution of this utility model;

[0020] Figure 1a This is a schematic structural diagram of the battery rack assembly positioning device of the utility model;

[0021] Figure 2 This is a schematic diagram of the structure of the palletizer of the utility model;

[0022] Figure 3 This is a schematic diagram of the structure of the adjustment frame of the palletizer of the utility model;

[0023] Figure 4 This is a schematic diagram of the installation position of the anti-fall mechanism of the lifting mechanism of the stacker crane of the utility model;

[0024] Figure 5 This is a schematic diagram of the structure of the anti-fall device of the lifting mechanism of the stacker crane of the utility model;

[0025] Figure 6 This is a schematic diagram of the side scissor assembly structure of the locking and unlocking mechanism;

[0026] Figure 7 This is a schematic diagram of the drag chain structure of the locking and unlocking mechanism;

[0027] Figure 8 This is a top view of the locking and unlocking mechanism of the present invention, showing the direction of movement of the locking and unlocking lock head;

[0028] Figure 9 This is the back side layout of the top plate of the locking and unlocking mechanism of the utility model;

[0029] Figure 9a This is a schematic diagram of the overall structure of the locking and unlocking mechanism of the utility model;

[0030] Figure 10 This is a schematic diagram of the layout of the double-layer electric cylinder on the back side of the top plate of the locking and unlocking mechanism of the utility model;

[0031] Figure 11 This is a schematic diagram of the installation of the four middle locks of the locking and unlocking mechanism of the utility model;

[0032] Figure 11a Schematic diagram of the partial structure of the bottom of the second layer plate of the unlocking mechanism of the utility model;

[0033] Figure 11b Schematic diagram of the bottom of the second layer plate of the locking and unlocking mechanism of the utility model;

[0034] Figure 12 This is a schematic diagram of the margin mechanism of the water and electricity joint of the utility model;

[0035] Figure 12a This is a schematic diagram of the margin mechanism of the water and electricity joint of the utility model;

[0036] Figure 12b This is a schematic diagram of the partial structure of the proximity switch of the water-electricity joint margin mechanism of the utility model.

[0037] In the picture:

[0038] 1. Battery rack; 11. Large battery; 12. Small battery; 21. Large battery positioning shaft; 22. Small battery positioning shaft; 3. Battery spacer; 4. Palletizer; 41. Palletizer lifting frame; 42. Adjustment frame; 43. Support fork; 441. Electric cylinder I; 442. Electric cylinder mounting base; 443. Push rod connecting block; 45. Guide rail VII; 46. Support fork telescopic motor reducer assembly; 47. Palletizer bracket; 49. Anti-drop device; 491. Anti-drop device mounting base; 492. Anti-drop guide rail; 6. Locking and unlocking mechanism; 61. First layer plate; 62. Second layer rack; 63. Z-axis lock; 64. Y-axis lock; 65. XY-axis lock; 66. Z-axis lifting plate; 67. Electric cylinder V; 671. Electric cylinder mounting base; 68. Guide shaft ;69. Electric cylinder III;610. Guide rail III;611. Electric cylinder IV;612. Guide rail IV;613. Electric cylinder VIII;614. Guide rail VIII;615. Y-axis push plate;616. Electromagnet;617. Side scissors fork;618. Fixed seat;619. Sliding seat;620. Guide rail VII;621. Pin shaft II;622. Drag chain;623. Channel;7. Water and electricity joint margin mechanism;71. Guide rail V;72. Slider III;73. Guide rail VI;74. Water and electricity joint upper and lower slide seats;75. Water and electricity joint;76. Slider IV;77. Driving mechanism;78. Cam positioning member;79. Pin shaft I;710. Water and electricity joint displacement column;711. Displacement slot;712. Proximity switch I;713. Sensor plate I. DETAILED DESCRIPTION

[0039] The following will be combined with the accompanying drawings in the examples of this application to clearly and completely describe the technical solutions in the embodiments. Obviously, the described embodiments are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0040] In the description of this application, it should be understood that the terms "center", "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0041] The terms "first," "second," and "third" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or to implicitly specify the quantity of the technical features indicated. Therefore, a feature specified as "first," "second," or "third" may explicitly or implicitly include one or more of such features.

[0042] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to direct connections, indirect connections through an intermediate medium, or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0043] In order to solve the technical problems in the prior art where battery racks are not compatible with batteries of different sizes and have inaccurate positioning, the present application provides an electric vehicle battery replacement system and battery rack.

[0044] See also Figure 1-Figure 1a In one possible embodiment, a battery rack assembly for an electric vehicle battery replacement system includes a battery rack 1 and multiple battery positioning devices. The battery rack 1 has a multi-layer structure, with battery positioning devices and battery pads 3 provided on each layer. The battery positioning devices include a large battery positioning shaft 21 and a small battery positioning shaft 22. The large battery positioning shaft 21 and the small battery positioning shaft 22 are respectively adapted to batteries 11 and 12 of different sizes or specifications and are installed on the battery rack 1. The battery pads 3 are installed on the battery rack 1 and are arranged corresponding to the battery positioning devices to support the large battery 11 and the small battery 12.

[0045] The electric vehicle battery replacement system includes a battery rack 1 and multiple battery positioning devices. The battery rack 1 has a multi-layer structure, with battery positioning devices and battery pads 3 installed on each layer. The battery positioning devices consist of a large battery positioning shaft 21 and a small battery positioning shaft 22, respectively suitable for batteries 11 and 12 of different sizes or specifications. Battery positioning shafts 21 and 22 are mounted on the battery rack 1 to ensure stable installation and positioning of the batteries. Battery pads 3 are mounted on the battery rack 1 and are arranged in correspondence with the battery positioning devices to support the batteries and ensure their stability during use.

[0046] In the above embodiment, the multi-layered design of the battery rack 1 enables the system to accommodate multiple batteries, and different positioning devices are used to adapt to batteries of different sizes. The large battery positioning axis 21 and the small battery positioning axis 22 are adapted to the battery size, ensuring the stable fixation of the battery on the battery rack 1. The battery pad 3 cooperates with the battery positioning device to effectively support the battery, preventing it from shaking or shifting during use, and ensuring the safety and stability of the battery during operation of the electric vehicle.

[0047] This system design can accommodate batteries of various specifications, improving the convenience and adaptability of electric vehicle battery replacement. In addition, the support provided by the battery pad 3 further enhances the stability of battery installation, reduces damage to the battery due to vibration or impact, and extends the battery life.

[0048] See also Figure 2 and Figure 3 In one possible embodiment, the system further includes a palletizer 4, which is arranged in correspondence with the battery rack 1 and comprises a palletizer lift frame 41, an adjustment frame 42 mounted on the palletizer lift frame 41, a support fork 43, an electric cylinder I 441, a guide rail VII 45, and a support fork telescopic motor reducer assembly 46. The two support forks 43 are mounted on two adjustment frames 42, respectively, which are each mounted to the palletizer lift frame 41 via the guide rail VII 45. The support fork telescopic motor reducer assembly 46 and the push rod of the electric cylinder I 441 are connected to the two adjustment frames 42 via a push rod connecting block 443, respectively, to drive the two adjustment frames 42 toward or away from each other, adjusting the spacing between the two support forks 43. The electric cylinder I 441 is mounted on the palletizer lift frame 41 via an electric cylinder mounting base 442, and the push rod is connected to the adjustment frame 42 via the push rod connecting block 443.

[0049] The electric vehicle battery replacement system also includes a palletizer 4. The palletizer 4 is arranged corresponding to the battery rack 1, and specifically includes a palletizer lifting frame 41, an adjustment frame 42, a support fork 43, an electric cylinder I 44, a guide rail VII 45, and a support fork telescopic motor reducer assembly 46. Two support forks 43 are provided, which are installed on the adjustment frame 42, and the adjustment frame 42 is installed on the palletizer lifting frame 41 through the guide rail VII 45. The support fork telescopic motor reducer assembly 46 is installed on the adjustment frame 42 to drive the support fork 43 to extend and retract. The electric cylinder I 44 is connected to the adjustment frame 42 through the push rod connecting block 443, thereby driving the adjustment frame 42 to move horizontally to adjust the horizontal position of the two support forks 43. The electric cylinder I 44 is installed on the palletizer lifting frame 41 through the electric cylinder mounting seat 442, and the push rod is connected to the adjustment frame 42 through the push rod connecting block 443 to achieve position adjustment of the support fork 43.

[0050] In the above embodiment, the palletizer 4, via its lifting frame 41, is able to flexibly move between different heights of the battery rack 1. The electric cylinder I 441, via a push rod connecting block 443, pushes the adjustment frame 42 to adjust the horizontal position of the fork. The fork telescopic motor-reducer assembly 46, mounted on the adjustment frame 42, drives the fork 43 to extend and retract, adjusting the distance the fork extends. The structural arrangement of the electric cylinder I 441, the fork telescopic motor-reducer assembly 46, the adjustment frame 42, and the fork 43 enables the system to precisely adjust the position and extension distance of the fork to accommodate batteries or battery packs of varying sizes.

[0051] The flexibility and precision of this palletizer system significantly improves battery replacement efficiency. By adjusting the spacing between the pallet forks, it can quickly adapt to batteries of different sizes, reducing the need for manual intervention and the risk of misoperation when installing or removing batteries.

[0052] In a possible embodiment, the palletizer 4 further includes a palletizer bracket 47, and the palletizer lifting frame 41 is installed on the palletizer bracket 47 through a palletizer lifting mechanism, and the palletizer lifting mechanism drives the palletizer lifting frame 41 to move up and down along the palletizer bracket 47. Figure 4 and Figure 5 The anti-fall device 49 is mounted on the palletizer lifting frame 41 via the anti-fall device mounting base 491. The anti-fall guide rail 492 is mounted on the column of the palletizer bracket 47, extending along the column in the same direction of movement as the palletizer lifting frame 41. When the palletizer lifting frame 41 reaches the set lower position, the gap in the anti-fall device 49 clamps the anti-fall guide rail 492, preventing the palletizer lifting frame 41 from falling.

[0053] In the above embodiment, the palletizer lifting frame 41 can be freely adjusted to different heights through the palletizer lifting mechanism, ensuring convenient and accurate battery replacement. The anti-fall device 49 is designed to automatically lock when the lifting frame 41 reaches the set position, preventing accidental falls and thus ensuring safe operation.

[0054] The system's anti-fall device effectively prevents the lifting frame from accidentally falling, ensuring operator safety. Furthermore, precise control of the lifting mechanism enables the Palletizer 4 to efficiently replace batteries in a variety of complex scenarios.

[0055] See also Figure 1 and Figure 6-9a The electric vehicle battery replacement system also includes a locking and unlocking mechanism 6, which is arranged on the battery tray 56. The battery tray 56 includes a first layer plate 61 and a second layer frame 62, and the first layer plate 61 is installed above the second layer frame 62; the locking and unlocking mechanism 6 includes a Z-direction lock head 63, a Y-direction lock head 64 and an XY-direction lock head 65 passing through the first layer plate 61; wherein the Z-direction lock head 63 is installed on the second layer frame 62 on the back of the first layer plate 61 through an I-shaped Z-direction lifting plate 66, and an electric cylinder V 67 is installed on the back of the first layer plate 61 or on the second layer frame 62. The output shaft of the electric cylinder V 67 is connected to the Z-direction lifting plate 66, driving the Z-direction lifting plate 66 and the Z-direction lock head 63 thereon to move up and down in a direction perpendicular to the plane of the first layer plate 61; a guide shaft 68 is provided on the Z-direction lifting plate 66, which passes through the first layer plate 61, and the Z-direction lifting plate 66 and the Z-direction lock head 63 thereon move along the guide shaft 68 Move up and down; an electric cylinder III 69, a guide rail III 610, an electric cylinder IV 611 and a guide rail IV 612 are arranged on the back of a layer of plate 61. The output shaft of the electric cylinder IV 611 is connected to the XY lock head 65. The XY lock head 65 is connected to the guide rail IV 612 and can slide along the guide rail IV 612 under the push of the electric cylinder IV 611. The output shaft of the electric cylinder III 69 is connected to the guide rail IV 612. The guide rail IV 612 is installed on the guide rail III 610 and can be moved by the electric cylinder. Pushed by Ⅲ69, it slides along guide rail Ⅲ610, and guide rail Ⅳ612 is perpendicular to guide rail Ⅲ610; an electric cylinder Ⅷ613, a guide rail Ⅷ614 and a Y-direction push plate 615 are set on the back of a layer plate 61, and the Y-direction lock head 64 is connected to the guide rail Ⅷ614 through the Y-direction push plate 615. The output shaft of the electric cylinder Ⅷ613 is connected to the Y-direction push plate 615 and can push the Y-direction push plate 615 and the Y-direction lock head 64 connected to it to slide along the guide rail Ⅷ614.

[0056] The locking and unlocking mechanism 6 utilizes locking heads in three directions (Z, Y, and XY) and their corresponding electric cylinders and guide rail systems to automatically lock and unlock the battery tray 56. The Z-direction locking head 63, driven by electric cylinder V 67, moves up and down along guide shaft 68, ensuring vertical locking or release of the battery tray 56. The Y-direction locking head 64 and the XY-direction locking head 65, driven by electric cylinders VIII 613 and IV 611, slide on corresponding guide rails VIII 614 and IV 612, respectively, to lock or release the battery tray 56 in the Y and XY directions. This multi-directional locking and unlocking design securely secures the battery tray 56 in three dimensions, ensuring safety and stability during battery replacement.

[0057] The locking and unlocking mechanism provides multi-directional locking methods, ensuring the safety and reliability of the battery during installation and replacement. The multi-directional locking design not only enhances the battery's secure retention, but also improves the operating efficiency of the entire system.

[0058] In one possible embodiment, there are four Z-direction locks 63, which are respectively arranged at the four ends of the I-shaped Z-direction lifting plate 66. The first layer plate 61 and the second layer frame 62 are connected by adsorption via electromagnets 616, and four electromagnets 616 are provided.

[0059] In the above embodiment, there are four Z-locking heads 63, positioned at the four I-shaped endpoints of the Z-lift plate 66, ensuring multiple locking points for the battery and enhancing stability. Electromagnets 616 provide additional suction force, tightly connecting the first-layer plate 61 and the second-layer frame 62 via electromagnetic attraction, further enhancing the stability and safety of the overall structure.

[0060] This design effectively improves the system's securement performance and operational safety by increasing the number of Z-axis locks 63 and introducing electromagnetic adsorption. This design provides a more stable and reliable battery fixation, especially in applications requiring higher strength and reliability.

[0061] See also Figure 6 In one possible embodiment, a side scissor assembly is provided between the first deck 61 and the second deck 62. The assembly includes two side scissor forks 617, two fixed seats 618, two sliding seats 619, and two guide rails 620. The two side scissor forks 617 are arranged in an X-shape and are fixed to the first deck 61 and the second deck 62 via fixed seats 618, respectively. The other ends of the side scissor forks 617 are connected to the guide rails 620 via sliding seats 619. The guide rails 620 are installed on the first deck 61 and the second deck 62.

[0062] The side scissor assembly, through its X-shaped structure, provides additional support and adjustment for the first-layer panel 61 and second-layer frame 62. During the installation and removal of the battery's first-layer panel, the side scissor assembly withstands the panel's weight and guides its smooth movement. By sliding the slide 619 on the guide rail 620, the side scissor assembly allows for flexible adjustment of the first-layer panel, ensuring stability and precise positioning during battery replacement.

[0063] In another embodiment, the number and size of the side scissor fork assemblies can be adjusted according to the weight and size of a battery layer. The design of the guide rail 620 and the sliding seat 619 can also be optimized as needed, and more durable or corrosion-resistant materials can be selected to adapt to applications in harsh environments.

[0064] In one possible embodiment, two sets of side scissor fork assemblies are provided, one set parallel to the other on opposite sides of the first layer plate 61 and the other set parallel to the second layer frame 62. These two sets of side scissor fork assemblies can provide support and adjustment functions for the battery tray at different positions, thereby achieving stable movement and locking of the first layer battery tray.

[0065] Two sets of side scissor forks are installed on opposite sides of the battery tray. This parallel arrangement further increases the tray's stability and load-bearing capacity. During the battery replacement process, the side scissor forks not only support the tray but also adjust its height and position vertically and horizontally to ensure that the first battery tray can be locked or unlocked smoothly.

[0066] In one possible embodiment, the two side scissor forks 617 are connected at the X-shaped center by a pin II 621. The pin 621 enables the side scissor forks 617 to be flexibly extended and adjusted through the rotation function of its center point, thereby enhancing the mobility of the support plate.

[0067] The X-shaped structure of the side scissor forks 617 is connected by a pin 621, allowing the side scissors to rotate about the pin, providing stable adjustment of the first deck in the vertical direction. During the battery replacement process, when the first deck moves up and down, the pin 621 allows the side scissor forks to automatically adjust to the height change of the first deck, maintaining the balance and stability of the first deck.

[0068] See also Figure 7 In one possible embodiment, the locking and unlocking mechanism further includes a drag chain 622, disposed between the first deck 61 and the second deck 62, for routing cables for the motor and switchgear. Drag chain 622 includes a channel 623, through which the cables are routed and protected, ensuring their safety and reliability during movement within the first deck.

[0069] The flexible design of the drag chain 622 connects the first-layer panel 61 and the second-layer frame 62. The channels 623 accommodate the cables for the motor and switchgear. As the battery's first-layer panel moves, the drag chain 622 expands and contracts with the panel, ensuring that the cables are not damaged or broken by the movement of the first-layer panel. Furthermore, the channels 623 provide excellent cable protection, preventing damage from the external environment.

[0070] See also Figure 12 and Figure 12aIn one possible embodiment, the battery rack 1 further includes a water-electricity connector margin mechanism 7 corresponding to the battery charging port installed between or on the layers. The water-electricity connector margin mechanism 7 includes a guide rail V 71 installed on the column of the battery rack 1, a slider III 72 installed on the guide rail V 71, and a guide rail VI 73 installed on the slider III 72 via an upper and lower water-electricity connector slide 74. The guide rail VI 73 is horizontally arranged, and the water-electricity connector 75 is installed on the guide rail VI 73 via a slider IV 76. The driving mechanism 77 drives the upper and lower water-electricity connector slide 74 or the slider III 72 to slide up and down along the guide rail V 71.

[0071] In the above embodiment, the water-electricity connector margin mechanism 7 achieves precise positioning of the water-electricity connector 75 via a guide rail system mounted on the column of the battery rack 1. The combined design of slider III 72, guide rail V 71, and guide rail VI 73 allows the water-electricity connector 75 to slide freely in both vertical and horizontal directions, thereby accurately docking with the battery charging port. The drive mechanism 77 achieves precise adjustment of the docking by controlling the movement of the water-electricity connector's upper and lower slide seat 74 or slider III 72.

[0072] This design effectively improves the efficiency and reliability of battery charging by precisely controlling the position of the water and electricity connector. The multi-directional sliding function of the water and electricity connector margin mechanism ensures a smooth docking process, reduces errors, and improves the degree of automation of the system.

[0073] See also Figure 12b In a possible embodiment, the water-electricity joint margin mechanism 7 further includes: a proximity switch I 712, mounted on the column of the battery rack 1; a sensor plate I 713, mounted on the upper and lower slide seats 74 of the water-electricity joint, and sliding up and down along the guide rail V 71 with the slide seat.

[0074] When the sensing piece I 713 contacts the proximity switch I 712 , the proximity switch I 712 is triggered and sends a signal to the control system to confirm that the water and electricity connector 75 is aligned with the battery charging port.

[0075] Sensor piece I 713 moves along guide rail V 71 with water and electricity connector slide 74. When it reaches a predetermined position, sensor piece I 713 cooperates with proximity switch I 712 to trigger the control system to stop the sliding operation. This design ensures that the water and electricity connector 75 precisely mates with the battery charging port, avoiding docking errors.

[0076] In one possible embodiment, the electric vehicle battery replacement system further includes a water-electricity connector margin mechanism corresponding to the battery charging port, which is installed between or on the battery rack layers. The margin mechanism includes a guide rail V installed on the battery rack column, a slider III installed on the guide rail V, and a guide rail VI installed on the slider III via an upper and lower slide of the water-electricity connector. The guide rail VI is arranged horizontally, and the water-electricity connector is installed on the guide rail VI via the slider IV. The driving mechanism drives the upper and lower slides of the water-electricity connector or the slider III to slide up and down along the guide rail V. The slider III is connected to a horizontally arranged cam positioning member, and the other end of the cam positioning member is placed in the displacement groove of the water-electricity connector displacement column via a pin shaft. The displacement groove includes two connected grooves, and the spacing between the two connected grooves and the guide rail V is different. The different spacings of the two grooves correspond to the charging ports of two batteries of different sizes.

[0077] In the above embodiment, the slider III is connected to the horizontally arranged cam positioning member 78. Through the operation of the driving mechanism, the slider III slides up and down along the guide rail V. The other end of the cam positioning member 78 is placed in the displacement groove 711 of the water-electricity connector displacement column 710 through the pin shaft I (79). As the slider III moves, the cam positioning member 78 pushes the water-electricity connector displacement column to move in the displacement groove through the pin shaft I 79. The two-section connected groove design of the displacement groove enables the water-electricity connector to automatically adjust its position according to the different sizes of the battery, thereby achieving precise docking with the charging port of batteries of different sizes. This design realizes the automatic adaptability of the water-electricity connector to batteries of different sizes through the two-section groove structure of the displacement groove, greatly improving the versatility and compatibility of the system. Regardless of the battery size, the system can be accurately docked, avoiding the tedious steps of manual adjustment, and improving charging efficiency and safety.

[0078] In one possible embodiment, a method for charging electric vehicle batteries of different specifications is provided, using any of the electric vehicle replacement battery systems. The method comprises the following steps:

[0079] Control the feeding battery to move between or on the layers of the battery rack, and control the large battery positioning axis or the small battery positioning axis to position the feeding battery according to the model of the feeding battery.

[0080] Control the Z-axis lock, Y-axis lock and XY-axis lock to lock the feed battery.

[0081] According to the model of the feeding battery, the driving mechanism is controlled to drive the slider III or the upper and lower slide seats of the water-electricity connector to keep it stationary or move it downward, so that the water-electricity connector is docked with the charging port of the feeding battery.

[0082] In the above embodiment, the positioning device in the electric vehicle battery replacement system first ensures the precise positioning of the feed battery on the battery rack. Next, the battery is multi-directionally locked by controlling the Z, Y, and XY locks to ensure stability during charging. Finally, depending on the battery model, the slider III or the water and electricity connector is driven up and down the slide seat to align and connect the water and electricity connector with the battery charging port, completing the charging operation.

[0083] This method achieves precise positioning and charging docking of batteries of different specifications through automated control, effectively reducing manual operation errors and time, improving charging efficiency and the intelligence of the system. Furthermore, the multi-directional locking design ensures the safety of the charging process and reduces the risk of charging failures caused by vibration or unstable connections.

[0084] In one possible embodiment, a battery replacement method is provided, wherein an electric vehicle is used to replace a battery system. The method includes the following steps:

[0085] Control the movement of fully charged batteries from the battery rack to the first set of battery trays on the double-compartment slide.

[0086] Control the double-bin slide to move under the feed battery of the electric vehicle to be replaced.

[0087] The control feed battery is moved to the second set of battery trays on the double-compartment slide.

[0088] Control the fully charged batteries to move from the first battery tray into the battery compartment of the electric vehicle.

[0089] The control feed battery is moved from the second battery tray into the battery rack and charged.

[0090] In the above embodiment, the control system first transfers the fully charged battery from the battery rack to the first set of battery trays on the dual-compartment slide. The slide then moves below the electric vehicle's feed battery. The position of the slide and the height of the trays are adjusted to ensure smooth transfer of the feed battery to the second set of battery trays. Next, the system controls the transfer of the fully charged battery from the first set of battery trays to the electric vehicle's battery compartment, completing the replacement process. Finally, the feed battery is moved to the battery rack, where it is automatically charged.

[0091] This battery swapping method uses a dual-compartment slide to efficiently swap between full and depleted batteries, significantly improving the speed and automation of the battery replacement process. The dual-stack battery tray design allows for seamless battery swapping, reducing vehicle downtime and improving overall operational efficiency.

[0092] Other embodiments of the present invention are as follows:

[0093] 1. Battery rack

[0094] 1. The battery rack is equipped with two battery positioning devices. The position of different batteries is adjusted by the stacker, so that the batteries are placed on two positioning shafts. The positioning shafts are installed on the battery rack by screws, so that the battery rack can be compatible with both large and small batteries and can charge the batteries. Figure 1 .

[0095] 2. Palletizer

[0096] 1. The palletizer's fork is equipped with a fork displacement mechanism. During the lifting process of the fork, the electric cylinder pushes the fork on the adjustment frame to achieve displacement adjustment of the fork perpendicular to the extension direction and the vertical direction. The entire extension mechanism of the two forks is placed on the adjustment frame, and the electric cylinder pushes the adjustment frame to ensure that the distance between the forks remains unchanged while achieving short-distance movement. Figure 2 and Figure 3 By adjusting the rack displacement, the two types of batteries are placed so that their charging ports are in the same position. Differentiate the V.1 water and electricity connector margin mechanism. This solution is to adapt the mobile battery to the fixed water and electricity connector position.

[0097] 2. The palletizer lifting mechanism has a new anti-fall device to prevent it from falling. By installing an anti-fall guide rail on the palletizer column and placing the anti-fall guide rail in the middle gap of the anti-fall device, if the lifting mechanism fails and falls due to a synchronous belt break or other reasons, the anti-fall device will clamp the anti-fall guide rail to prevent the lifting frame from falling, thereby improving the operation safety and emergency handling capabilities of the palletizer. Figure 4 Figure 5 .

[0098] 3. Lock and Unlock

[0099] 1. The locking and unlocking mechanism can adapt to two types of batteries of different sizes. The locking and unlocking lock head is pushed by the electric cylinder to realize the locking and unlocking operation for two types of batteries. When removing and installing a small battery, the locking and unlocking connector moves inward under the push of the electric cylinder. When removing and installing a large battery, the locking and unlocking connector moves to the outer edge. Figure 8 The back of the unlocking layer is equipped with an electric cylinder to drive the guide rail slider mechanism, which is connected to the unlocking lock head through the push plate. It is suitable for loading and unloading two types of batteries, large and small. At the same time, four electromagnets are arranged to ensure that the unlocking top layer will not deviate during operation. Figure 9 At the same time, in order to realize the removal and installation of large batteries, the two corner locks move in the "L" direction (XY direction), and two layers of electric cylinders are arranged to push and control their movement in two directions and reach the specified position. Figure 10 .

[0100] When locking and unlocking the lock, the lock moves to a position suitable for the corresponding battery and is lifted by the electric cylinder. The four middle locks are lifted at the same time by the electric cylinder connected to the Z-direction lifting plate, saving internal space for locking and unlocking. Then the 12 locks perform the locking and unlocking operation.

[0101] 2. The four locking and unlocking heads are connected through an "I"-shaped Z-direction lifting plate. The Z-direction lifting plate determines the Z-direction movement direction through two guide shafts and is connected to the top plate through the electric cylinder and the electric cylinder mounting base. The electric cylinder is used to realize the lifting of the four locking and unlocking heads. Figure 11 .

[0102] 4. Water and electricity joint margin mechanism

[0103] 1. The water and electricity joints are equipped with a margin mechanism. Figure 12 and Figure 12a When charging, by controlling the falling distance of the water and electricity connector and the extending distance of the water and electricity connector, it can be used to charge two batteries placed on the battery rack. This solution is applicable to the case 2.1 where the mobile adjustment rack of the palletizer is not included, and the position of the water and electricity connector is moved to adapt to the two sizes of batteries.

[0104] As another implementation method, the battery swapping process and mechanism at the battery swapping station are described as follows;

[0105] The utility model provides a battery swapping station system for reducing the occupied volume of the battery swapping station without reducing the battery swapping time. The existing technologies include:

[0106] 1. The battery swap station sets up a cache position for placing the removed batteries. After the feed battery removed from the vehicle is placed in the cache position, the fully charged battery is moved from the docking position to the RGV, and then the fully charged battery is installed on the vehicle. It is best to move the cache position battery to the battery compartment.

[0107] Disadvantages of existing technology 1: The cache space temporarily takes up more space, and the box of the battery swap station also needs to be larger;

[0108] 2. Cancel the docking position, put the checked battery into the battery compartment, and then move a new battery to the RGV;

[0109] Disadvantages of existing technology 2: The battery replacement time is too long. After the battery on the car is disassembled, it needs to be sent to the battery warehouse first, and then another battery is transported, which adds more time and is not a good experience for customers.

[0110] The present invention describes a battery replacement process and mechanism, which eliminates the cache position, reduces the area occupied by the battery replacement station and the size of the box, and adopts a double-layer design from the docking position to the RGV conveying mechanism. Before battery replacement, a fully charged battery is prepared on the lower layer, and the removed feed battery is moved from the RGV to the upper layer. The feed battery is transported from the upper layer to the docking position, and the fully charged battery is transported from the lower layer to the RGV.

[0111] A1 and A2, B1 and B2 are two groups of battery lifting mechanisms, with upper and lower layers, which reciprocate left and right on the slide rails through belts;

[0112] A1 and A2 are responsible for transporting the dismantled old batteries, while B1 and B2 are responsible for transporting the fully charged new batteries to be installed.

[0113] First, place the fully charged new battery on B1B2, move A1 and A2 to the removed feed battery, lift the battery, then move A1A2 to the right and B1B2 to the left synchronously; the two sets of lifting mechanisms move synchronously to reduce the transportation time; after the battery replacement is completed, move the A1A2 battery to the battery rack, A1A2 to the left, and B1B2 to the right to return to the starting point.

[0114] 1. This solution adopts a two-layer conveying mechanism design, which reduces the number of cache positions without reducing the battery replacement speed, reducing the cost of the battery replacement station while retaining the battery replacement experience; it adopts a double-layer conveying mechanism, which is in the form of a battery replacement cart instead of a double-layer conveyor belt; it adopts a lifting and moving method to transport batteries.

[0115] Finally, it should be noted that the various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0116] The above embodiments are only used to illustrate the technical solutions of the present application and are not intended to limit the same. Although the present application has been described in detail with reference to the preferred embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present application can still be modified or some technical features can be replaced by equivalents without departing from the spirit of the technical solutions of the present application. They should all be included in the scope of the technical solutions for which protection is requested in the present application.

Claims

1. A battery rack assembly for an electric vehicle battery replacement system, characterized in that: The battery rack (1) is a multi-layer structure; It comprises: a water-electricity joint margin mechanism (7) corresponding to the battery charging port, which is installed between or on the layers of the battery rack (1); the water-electricity joint margin mechanism (7) is installed on the column of the battery rack (1); The water-electricity joint margin mechanism (7) comprises: a guide rail V (71) mounted on a battery rack column, a slider III (72) mounted on the guide rail V (71), a guide rail VI (73) mounted on the slider III (72) via a water-electricity joint upper and lower slide seat (74), the guide rail VI (73) being arranged horizontally, and the water-electricity joint (75) being mounted on the guide rail VI (73) via a slider IV (76); a driving mechanism (77) driving the water-electricity joint upper and lower slide seat (74) or the slider III (72) to slide up and down along the guide rail V (71); The slider III (72) is connected to the horizontally arranged cam positioning member (78). The other end of the cam positioning member (78) is placed in the displacement groove (711) of the water and electricity joint displacement column (710) through the pin shaft I (79). The displacement groove (711) includes two sections of connected grooves. The distances between the two sections of connected grooves and the guide rail V (71) are different. The different distances at the two ends correspond to the charging ports of two batteries of different sizes. The locking and unlocking mechanism is arranged on a battery support plate, and the battery support plate is arranged on each layer of the battery rack (1); the battery support plate includes a first layer plate (61) and a second layer rack (62), and the first layer plate (61) is installed above the second layer rack (62); The locking and unlocking mechanism (6) includes a Y-direction locking head (64) and an XY-direction locking head (65) passing through a layer of plate (61); An electric cylinder III (69), a guide rail III (610), an electric cylinder IV (611) and a guide rail IV (612) are provided on the back of a layer plate (61). The output shaft of the electric cylinder IV (611) is connected to the XY-direction lock head (65). The XY-direction lock head (65) is connected to the guide rail IV (612) and can slide along the guide rail IV (612) under the push of the electric cylinder IV (611). An electric cylinder VIII (613), a guide rail VIII (614) and a Y-direction push plate (615) are provided on the back of a layer plate (61). The Y-direction lock head (64) is connected to the guide rail VIII (614) through the Y-direction push plate (615). The output shaft of the electric cylinder VIII (613) is connected to the Y-direction push plate (615) and can push the Y-direction push plate (615) and the Y-direction lock head (64) connected thereto to slide along the guide rail VIII (614).

2. The battery rack assembly of the electric vehicle battery replacement system according to claim 1, characterized in that: It also includes a plurality of battery positioning devices, with each layer of the battery rack (1) being provided with a battery positioning device and a battery pad (3); The battery positioning device comprises a large battery positioning shaft (21) and a small battery positioning shaft (22). The large battery positioning shaft (21) and the small battery positioning shaft (22) are mounted on the battery rack (1) and are respectively adapted to large batteries (11) and small batteries (12) of different sizes or specifications.

3. The battery rack assembly of the electric vehicle battery replacement system according to claim 2, characterized in that: Also includes: The battery pad (3) is mounted on the battery rack (1) and is arranged corresponding to the battery positioning device, and is used to support the battery.

4. The battery rack assembly of the electric vehicle battery replacement system according to claim 3, characterized in that: The water and electricity joint margin mechanism (7) also includes: Proximity switch I (712), mounted on a column of the battery rack (1); Induction piece I (713), mounted on the upper and lower sliding seats (74) of the water and electricity joint; When the sensing piece I (713) slides up and down along the guide rail V (76) along with the water and electricity joint upper and lower sliding seat (74) until it contacts the proximity switch I (712), the proximity switch I (712) is triggered to send a signal to the control system.

5. The battery rack assembly of the electric vehicle battery replacement system according to claim 4, characterized in that: The water and electricity connector (75) corresponds to the charging port of the large battery or the small battery.

6. The battery rack assembly of the electric vehicle battery replacement system according to claim 5, characterized in that: The locking and unlocking mechanism (6) further comprises a Z-direction locking head (63) passing through a layer of plate (61); wherein the Z-direction locking head (63) is mounted on an I-shaped Z-direction lifting plate (66) on the back of the layer of plate (61); an electric cylinder V (67) is mounted on the back of the layer of plate (61) via an electric cylinder V electric cylinder mounting seat (671); an output shaft of the electric cylinder V (67) is connected to the Z-direction lifting plate (66), driving the Z-direction lifting plate (66) and the Z-direction locking head (63) thereon to move up and down in a direction perpendicular to the plane of the layer of plate (61).

7. An electric vehicle battery replacement system, characterized in that: The battery rack assembly comprises the battery rack assembly according to any one of claims 1 to 6, and further comprises: a palletizer (4), the palletizer (4) being arranged corresponding to the battery rack, comprising: a palletizer lifting frame (41) and an adjustment frame (42) mounted on the palletizer lifting frame (41), a support fork (43), an electric cylinder I (441), a guide rail VII (45) and a support fork telescopic motor reducer assembly (46); Two supporting forks (43) are provided, and the two supporting forks (43) are mounted on the adjusting frame (42), and the adjusting frame (42) is mounted on the palletizer lifting frame (41) through the guide rail VII (45); The support fork telescopic motor reducer assembly (46) is installed on the adjustment frame (42) to drive the support fork (43) to extend and retract. The push rod of the electric cylinder I (441) is connected to the adjustment frame (42) to drive the adjustment frame (42) to move horizontally to adjust the positions of the two support forks (43). The electric cylinder I (441) is mounted on the palletizer lifting frame (41) through the electric cylinder I electric cylinder mounting base (442); the push rod of the electric cylinder I (441) is connected to the adjustment frame (42) through the push rod connecting block (443).

8. The electric vehicle battery replacement system according to claim 7, characterized in that: The palletizer (4) further includes a palletizer bracket (47), a palletizer lifting frame (41) being mounted on the palletizer bracket (47) via a palletizer lifting mechanism, and the palletizer lifting mechanism driving the palletizer lifting frame (41) to move up and down along the palletizer bracket (47); It also includes: a fall arrester (49), which is mounted on the palletizer lifting frame (41) through a fall arrester mounting seat (491); The anti-fall guide rail (492) is mounted on the column of the palletizer support (47) and extends along the column in the direction of movement of the palletizer lifting frame (41); The anti-fall device (49) has a gap in the middle, and the anti-fall guide rail (492) is placed in the gap of the anti-fall device (49). When the palletizer lifting frame (41) reaches the set position below, the gap clamps the anti-fall guide rail (492) to prevent the palletizer lifting frame (41) from falling.

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