Mechanical switching device for batteries of electric vehicle

Abstract

The utility model relates to the technical field of electric vehicle power management, in particular to an electric vehicle battery mechanical switching device which comprises a plurality of sets of communication contacts, a mode adjusting mechanism, an operation installation disc and a transmission mechanism. The other end of the battery is electrically connected with the plurality of batteries through a mode adjusting mechanism; the mode adjusting mechanism comprises an adjusting disc, a plurality of contacts are distributed at the two ends of the adjusting disc at equal intervals in the circumferential direction, the plurality of contacts form a plurality of gear contact combinations corresponding to different working modes of the battery pack, and each group of communicating contacts are symmetrically distributed on the two sides of the adjusting disc; the transmission mechanism comprises an adjusting gear arranged on the edge of the end face of the adjusting disc and a gear transmission rod meshed with the adjusting gear. According to the utility model, the transmission mechanism drives the adjusting disc and the contacts at the two ends of the adjusting disc to rotate so as to replace the gear contact combination corresponding to the plurality of groups of communicated contacts, so that the working mode switching of the battery pack is realized.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle power management technology, specifically to an electric vehicle battery mechanical switching device. Background Technology

[0002] With the development of technology, economy, and living environment, two-wheeled electric vehicles have demonstrated unique advantages in various transportation scenarios due to their convenience and low cost. Whether in lower-tier cities and towns with low public transportation network density or in higher-tier cities with well-developed public transportation but traffic congestion, there is a broad market demand for two-wheeled electric vehicles.

[0003] Two-wheeled electric vehicles typically have multiple lead-acid batteries to power them. In actual use, it is possible for one of the batteries to malfunction. In this case, to prevent the malfunctioning battery from affecting the use of other batteries and the operation of the electric vehicle, it is best to disconnect the malfunctioning battery from the other batteries.

[0004] A patent with publication number CN202021125U discloses a multi-power switching device for electric vehicles, which includes an electromagnetic relay, multiple sets of batteries, a multi-position switching switch that matches the number of batteries, and a power supply circuit for powering the electric vehicle. Each pair of batteries is connected to the input terminal of the power supply circuit of the electric vehicle through an electromagnetic relay. The input terminal of each position of the switching switch is connected to the positive terminal of a set of batteries corresponding to it. The output terminal of the switching switch is connected to the positive terminal of the armature coil of the electromagnetic relay. The negative terminal of the armature coil is connected to a common negative terminal of the power supply, which is connected to the negative terminal of the input terminal of the power supply circuit of the electric vehicle. The positive terminal of the input terminal of the power supply circuit of the electric vehicle is connected to the common terminal of the output contacts of the electromagnetic relay.

[0005] The above method achieves power switching and extends riding time, but it relies on numerous electronic components and circuits. These added circuits significantly increase the probability of malfunctions such as poor electrical contact. Therefore, a mechanical switching device can be used to replace electronic components and switch the battery pack between different operating modes. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies and provide a mechanical switching device for electric vehicle batteries. This device can block the use of abnormal batteries through mechanical structures and switch to the emergency working mode of the battery pack, thereby preventing abnormal batteries from having an excessive impact on the performance of the entire battery pack and the operation of the two-wheeled electric vehicle.

[0007] To solve the above problems, the present invention adopts the following solution:

[0008] A mechanical switching device for electric vehicle batteries includes multiple sets of connecting contacts, a mode adjustment mechanism, an operating mounting plate, and a transmission mechanism. One end of each set of connecting contacts is electrically connected to a battery, and the other end is electrically connected between multiple batteries via the mode adjustment mechanism. The mode adjustment mechanism includes an adjustment disc with multiple contacts evenly spaced along its circumference at both ends. These contacts form several sets of gear contact combinations, with different gear contact combinations corresponding to different operating modes of the battery pack. Each set of connecting contacts is symmetrically distributed on both sides of the adjustment disc. The transmission mechanism includes an adjustment gear disposed on the edge of the adjustment disc's end face and a gear transmission rod meshing with the adjustment gear. The transmission mechanism drives the adjustment disc and the contacts at both ends to rotate, thereby changing the gear contact combinations corresponding to the multiple sets of connecting contacts and achieving battery pack operating mode switching.

[0009] In the above solution, the direct series connection of multiple batteries in the battery pack is changed to selective electrical connection between multiple batteries through a switching device. Specifically, the transmission mechanism drives the adjustment disc and the contacts at both ends to rotate, thereby changing the gear contact combination corresponding to multiple sets of connecting contact heads. Each gear contact combination corresponds to a different working mode. Therefore, when a battery in the battery pack is abnormal, it can be rotated to the corresponding gear contact combination to cut off the connection of the abnormal battery.

[0010] Preferably, the operating mounting plate is symmetrically designed, including two shielding plates, with an installation space between the two shielding plates for installing an adjustment disc. The adjustment disc is coaxially mounted with the two shielding plates, and the two shielding plates have connecting through holes that allow the connecting contact head to pass through and make contact with the contact point.

[0011] In the above setup, the adjusting disc is installed between the two shielding discs, so that the contacts at both ends of the adjusting disc are shielded by the shielding discs, forming an effective shielding protection to prevent dust and impurities from sticking to the contacts and affecting the electrical contact effect.

[0012] Preferably, the edges of the two shielding discs are connected by protruding connecting blocks, and the protruding connecting blocks are provided with pulling ropes that can pull the two shielding discs to rotate.

[0013] The above settings allow the operating installation plate to rotate. Specifically, by pulling the rope, the two blocking plates are rotated, causing the connecting contact head to slide out or into the connecting through hole. This ensures that the connecting contact head will slide in and make contact with the contacts when the battery pack needs to be activated, and that the connecting contact head will not make contact with the contacts when the battery pack is deactivated.

[0014] Preferably, the shielding plate near the adjusting gear has a 45° fan-shaped clearance notch.

[0015] A clearance notch is provided to allow the gear transmission rod to mesh with the adjusting gear, while avoiding excessive exposure of the adjusting disc.

[0016] Preferably, the inner wall of the connecting through hole is chamfered, and the end of the connecting contact head near the contact point is spherical.

[0017] The above configuration allows the connecting contact head to slide smoothly into the connecting through hole, ensuring smooth switch operation.

[0018] Preferably, the surface of the connecting contact head is covered with a conductive elastic layer.

[0019] The above configuration is designed to generate a certain amount of elastic pressure through the conductive elastic layer, ensuring close contact with the contacts.

[0020] Preferably, the contact point is reused in different gear contact point combinations.

[0021] The above settings are designed to make effective use of the contact points, ensuring the availability of multiple different working modes while minimizing space usage and maximizing space utilization.

[0022] Preferably, the gear position contact assembly achieves different working modes by adjusting the wires inside the disc.

[0023] The above setup is designed to enable different modes of line connection while further improving the space utilization of the entire switching device.

[0024] The beneficial effects of this utility model are as follows:

[0025] This invention uses a gear transmission rod to drive an adjusting disc meshing with its gears to rotate, thereby causing the contacts at both ends to rotate and change positions. This allows for the replacement of gear contact combinations corresponding to multiple sets of connected contact heads. Each set of gear contact combinations corresponds to a different battery pack operating mode. Therefore, when a battery abnormality is detected during the operation of the electric vehicle, the switching device can quickly switch to emergency mode to disconnect the abnormal battery. This reduces the adverse effects of the abnormal battery on other normal batteries and avoids the possibility of sudden power stoppage of the electric vehicle.

[0026] Meanwhile, the switching device uses a mechanical structure to switch the battery pack's operating mode, avoiding the use of electronic components such as electromagnetic relays, thus reducing the probability of battery pack failure due to the failure of these electronic components. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the internal structure of the switching device and the battery pack of this utility model.

[0028] Figure 2 This is a schematic diagram of the mode adjustment structure of this utility model;

[0029] Figure 3 This is a schematic diagram of the structure of the operating installation panel of this utility model.

[0030] Reference numerals: 11 connecting contact head, 12 mode adjustment mechanism, 13 operating mounting plate, 121 adjusting disc, 122 gear position contact assembly, 1221 contact, 131 shielding plate, 1311 connecting through hole, 132 installation space, 133 protruding connecting block, 134 pulling rope, 20 transmission mechanism, 21 adjusting gear, 22 gear transmission rod, 23 clearance notch. Detailed Implementation

[0031] Example 1: Reference Figures 1-3 This embodiment provides a mechanical battery switching device for electric vehicles. This device is mainly used in the electric vehicle field, and is particularly suitable for two-wheeled electric vehicles powered by multiple batteries. The switching device is installed between the left and right battery packs and includes four sets of connecting contact heads 11, a mode adjustment mechanism 12, and an operating mounting plate 13. The technical features of each component are as follows:

[0032] Connecting contact head 11: It adopts a symmetrical layout, with each set of connecting contact heads 11 symmetrically arranged on both sides of the mode adjustment mechanism 12; the connecting contact head 11 is made of highly conductive gold-plated copper alloy, and two pairs of positive and negative connecting contact heads 11 are set on each side; the connecting contact head 11 is connected to the battery terminal through a waterproof electrical connector on it to ensure that the contact resistance is ≤0.5mΩ; each set of connecting contact heads 11 adopts a coaxial rotation design, and the rotation torque is controlled within 0.8N•m; the four connecting contact heads 11 on each side are distributed in an equally divided arc shape to ensure uniform force distribution.

[0033] The design of this switching device allows for flexible configuration of the number of connecting contacts 11 according to actual application requirements, and maintains a symmetrical distribution on both sides of the mode adjustment mechanism 12.

[0034] Key component design of mode adjustment mechanism 12:

[0035] Adjustment disc 121: Made of wear-resistant engineering plastic, with a diameter of 80-100mm and a thickness of 15-20mm;

[0036] Contact 1221 distribution: Multiple contacts 1221 are evenly distributed along the circumference at both ends of the adjustment disk 121 (only the contacts at one end of the adjustment disk are shown in the figure). The contacts 1221 are made of silver-plated copper alloy and have a contact resistance of ≤0.3mΩ.

[0037] Gear combination: Multiple contacts 1221 form several gear contact combinations 122. The contacts 1221 of each gear contact combination 122 are symmetrically distributed at both ends of the adjustment disc 121, and the number of contacts 1221 of each gear contact combination 122 matches the number of connected contact heads 11.

[0038] Circuit design: The contact combination 122 of each gear position realizes different modes of circuit connection by adjusting the wires (cross-sectional area ≥ 2.5mm²) inside the disc 121. The contact 1221 can be reused in different contact combinations 122 of different gear positions, thereby improving space utilization.

[0039] When a battery in the battery pack malfunctions, the switching device can rotate the adjustment disk 121 via a stepper motor (angle 0-360°, step angle 15°) to reconnect the battery pack. The stepper motor drive ensures positioning accuracy within ±0.5°, and the contact pressure of the contact point 1221 is maintained within the range of 0.6-0.8MPa.

[0040] To achieve precise control of the adjusting disc 121, this embodiment features a dedicated transmission mechanism 20. A fully circumferential adjusting gear 21, machined from the edge of one circular end face of the adjusting disc 121, is precision carburized and quenched. This gear, along with a gear transmission rod 22 (module 1.5, number of teeth 20) made of 20CrMnTi, forms a 2:1 reduction ratio, with the gear pair backlash controlled between 0.1-0.15mm. The gear transmission rod 22 is supported at both ends by deep groove ball bearings (6202-2Z) and extends to the front of the electric vehicle. This embodiment provides two control schemes: In manual control, it connects to the adjusting operating component at the front of the vehicle via an SAE 6-tooth spline, with an operating torque ≤2N•m; in automatic control, a stepper motor (e.g., a 12-stepper motor, torque ≥0.4N•m) or a servo motor (power 20-100W) can be selected for direct drive, enabling remote automated control. This design enables this embodiment to automatically optimize battery pack switching based on real-time monitoring data (indexing accuracy ±1°). To improve the protection performance of the switching device, the shielding plate 131 near the adjusting gear 21 is designed with a 45° fan-shaped clearance notch 23. The edge of the clearance notch 23 is provided with a sealing lip made of nitrile rubber (1mm thick), which provides IP54 dustproof effect (sealing ring compression rate 15-20%) while ensuring gear meshing (overlap coefficient 1.2-1.4).

[0041] The operating mounting plate 13 adopts a symmetrical design. Its core structure includes two precision injection-molded shielding plates 131, forming a cylindrical mounting space 132 (diameter 82-85mm, axial clearance 0.2-0.3mm) between the two shielding plates 131 for mounting the adjusting disc 121. The inner wall of the mounting space 132 is provided with an annular sealing groove (depth 1.5mm, width 2mm) for installing the sealing ring. The shielding plate 131 is provided with a connecting through hole 1311 that allows the connecting contact head 11 to pass through and contact the contact point 1221.

[0042] The mechanical operation design of the operating mounting plate 13 also includes a quick-switching mechanism. Protruding connecting blocks 133 are connected to the edges of the two shielding plates 131 via high-strength bolts (strength grade 8.8). The protruding connecting blocks 133 are designed with precision positioning grooves for fixing the wire rope, and a high-strength tension rope 134 is connected via a special clamp. The guiding system of the tension rope 134 uses a guide wheel assembly supported by sealed bearings (6000-2RS) to ensure smooth transmission and extend service life. When the manual control scheme is selected, the tension rope 134 is connected to the starting operation components in the front of the vehicle; when the electric control scheme is adopted, a small servo motor (torque 0.2-0.4 N•m) can be configured to achieve automated control, with a system response time ≤200ms.

[0043] Regarding contact interface optimization, the inner wall of the connecting through-hole 1311 adopts a 15° chamfer design (depth 0.5-0.8mm) and undergoes anodizing treatment. The end of the connecting contact head 11 near the contact point 1221 adopts a spherical design and is plated with a 3-5μm gold layer, controlling the coefficient of friction between 0.1-0.15 and the operating force below 5N, ensuring a smooth and reliable conversion process. To improve conductivity, the surface of the connecting contact head 11 is covered with a 0.2-0.3mm thick conductive elastic layer, which can be selected from graphene composite materials (volume resistivity ≤10^-3 Ω•cm, elastic deformation 20-30%), PEDOT:PSS doped conductive polymer materials (conductivity >1000 S / cm), or beryllium copper alloy (yield strength ≥200MPa), etc. This embodiment uses a composite material of 8-12 layers of graphene and silicone rubber, which has excellent lateral conductivity (>2000 S / cm). When the connecting contact head 11 enters the connecting through hole 1311, the conductive elastic layer generates an elastic pressure of 2-3N and contacts the contact point 1221, ensuring that the contact resistance is <0.3mΩ and reliably supporting the transmission of instantaneous current ≥100A.

[0044] The battery switching process in this embodiment is as follows:

[0045] Basic operating procedures:

[0046] 1. Startup process:

[0047] In manual control: Operate the start-up control unit at the front of the vehicle, and pull the pull rope 134 (travel 15-20mm) to drive the two shielding discs 131 to rotate synchronously.

[0048] In automatic control mode: The control system drives the servo motor to achieve precise synchronous rotation of the two blocking discs 131.

[0049] 2. Contact Establishment:

[0050] The connecting contact 11 slides into the corresponding connecting through hole 1311 at a speed of 0.2-0.3 m / s and makes contact with the corresponding contact 1221 to establish communication.

[0051] Positioning accuracy ≤ 0.1mm, contact pressure maintained at 0.6-0.8MPa

[0052] The monitoring system collects battery status data in real time using high-precision sensors.

[0053] 3. Mode switching:

[0054] Manual mode: Adjust the operating components via the front of the vehicle (maximum operating torque 2 N•m).

[0055] Automatic mode: powered by a stepper motor or servo motor (60-120 rpm).

[0056] The transmission mechanism 20 drives the adjusting disc 121 to rotate precisely to the target position (positioning accuracy ±1°).

[0057] The gear position contact assembly 122 forms a stable contact with the connecting contact head 11 (contact resistance ≤ 0.3mΩ).

[0058] The gear shift contact combination 122 is designed with the following working modes:

[0059] The system includes a standard 48V mode (four batteries in series), a 36V emergency mode (three batteries in series, automatically skipping faulty batteries), a 24V emergency mode (two batteries in series), and a diagnostic mode for evaluating the performance of a single battery. Each mode has a corresponding 1221 contact connection strategy to ensure reliable operation of the electric vehicle under various operating conditions.

[0060] This embodiment employs a series of core technical safeguards. Each group of contacts 1221 is equipped with a clear polarity marking and integrates a reverse connection protection mechanism; sufficient safety distance is maintained between contacts 1221 to prevent short circuit risks. The switching mechanism adopts a unidirectional rotation design to avoid poor contact caused by repeated switching; an overlap area is set during the transition of contacts 1211 to ensure power supply continuity; all positions are equipped with clear markings and reliable positioning structures.

[0061] It should be noted that the specific parameters involved in this embodiment are preferred implementations and can be adjusted appropriately according to actual application requirements. For example, the battery specifications can be selected according to different voltage levels based on the vehicle requirements, the contact safety distance can be adjusted accordingly based on the working voltage level, and the reduction ratio and operating torque of the transmission mechanism can be adjusted based on operational convenience requirements.

[0062] This embodiment is mainly optimized for two-wheeled electric vehicle application scenarios. Under the premise of ensuring safety and reliability, all technical parameters can be reasonably adjusted to adapt to different application needs.

Claims

1. An electric vehicle battery mechanical switching device, characterized by, The utility model relates to a battery pack mode switching device, including multiple groups of communication contact (11), mode adjusting mechanism (12), operation mounting disc (13) and transmission mechanism (20), one end of each group communication contact (11) is connected with battery, and the other end realizes the electrical connection between multiple batteries through mode adjusting mechanism (12), mode adjusting mechanism (12) includes adjusting disc (121), and multiple contacts (1221) are distributed in the circumferential direction of the both ends of adjusting disc (121) equally, and multiple contacts (1221) form several groups of gear contact combination (122), and different gear contact combination (122) corresponds the different working mode of battery group, and each group communication contact (11) is distributed on the both sides of adjusting disc (121) symmetrically, transmission mechanism (20) includes the adjusting gear (21) of setting in the end face edge of adjusting disc (121) and the gear transmission rod (22) of meshing with adjusting gear (21), and the contact (1221) of adjusting disc (121) and both ends is driven to rotate through transmission mechanism (20) with gear contact combination (122) corresponding multiple groups of communication contact (11) is replaced, and the working mode switching of battery group is realized.

2. The mechanical battery switching device for electric vehicles according to claim 1, characterized in that, The operation mounting disc (13) is symmetrically designed, including two shielding discs (131), the installation space (132) for installing adjusting disc (121) is formed between two shielding discs (131), adjusting disc (121) is coaxially installed with two shielding discs (131), and two shielding discs (131) are provided with connecting through holes (1311) that can make communication contact (11) pass through to contact contact (1221).

3. The mechanical battery switching device for electric vehicles according to claim 2, characterized in that, Two shielding discs (131) edges are connected with convex link blocks (133), and convex link blocks (133) are provided with pull ropes (134) that can pull two shielding discs (131) to rotate.

4. The mechanical battery switching device for electric vehicles of claim 2, wherein, The shielding disc (131) near the side of adjusting gear (21) is provided with a fan-shaped gap (23).

5. The mechanical battery switching device for electric vehicles of claim 2, wherein, The inner wall of connecting through hole (1311) adopts chamfer design, and the end of communication contact (11) near contact (1221) adopts spherical surface design.

6. The mechanical battery switching device for electric vehicles according to claim 5, characterized in that, The surface of communication contact (11) is coated with a conductive elastic layer.

7. The mechanical battery switching device for electric vehicles according to any of claims 1-6, characterized in that, The contact (1221) is repeatedly used in different gear contact combinations (122).

8. The electric vehicle battery mechanical switching device of claim 1, wherein, The gear contact combination (122) realizes the line connection of different working modes through the wire inside adjusting disc (121).

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