A double-sided high-voltage electrical system for a container electric container lift truck

Abstract

This utility model discloses a dual-sided battery swapping high-voltage electrical system for electric stackers of empty containers, belonging to the technical field of electric products for engineering machinery. The system includes a dual-sided interchangeable high-voltage battery pack system, a battery swapping connector, a high-voltage switching box, a high-voltage distribution box, an execution load module, a power conversion module, a temperature control module, and dual-sided charging bases on the chassis. The dual-sided interchangeable high-voltage battery pack system connects the battery management unit and the heat dissipation unit through a high-voltage junction box. The battery swapping connector enables the battery pack to interface with the chassis high-voltage system. The high-voltage switching box controls the selective output of power from both sides through a switching component. The high-voltage distribution box distributes power to the drive, lifting, and other execution loads, as well as the temperature control and low-voltage conversion modules. The dual-sided charging bases on the chassis support synchronous charging when the battery pack is not disassembled. This utility model solves the problems of short battery life and machine shutdown after a failure in traditional single-sided battery swapping systems, improving the operational continuity and maintenance flexibility of electric stackers of empty containers, and is suitable for high-intensity container handling scenarios in ports.

Description

Technical Field

[0001] This utility model relates to the field of electric products for engineering machinery, specifically a dual-sided high-voltage electrical system for electric stackers of empty containers. It is suitable for the high-voltage power supply, switching and management of electric stackers of empty containers, improving the equipment's endurance and operational reliability. Background Technology

[0002] As a core mobile crane equipment for container handling in ports, the operating efficiency and endurance of electric stackers for empty containers directly affect the port's logistics turnover efficiency. Currently, the high-voltage battery swapping systems of electric stackers for empty containers on the market generally adopt a single-sided battery swapping design, that is, a single battery pack is installed on only one side of the chassis. This design has two major problems: First, the power capacity of a single-sided battery pack is limited, resulting in poor equipment endurance, and frequent battery swapping seriously affects the continuity of operations; second, when a single-sided battery pack fails, the entire stacker cannot operate due to the loss of high-voltage power supply, requiring shutdown for maintenance, which significantly reduces equipment utilization.

[0003] Existing technologies, such as the "Battery Pack for an Electric Stacker" disclosed in patent CN221900123U, while achieving rapid battery pack replacement and independent cooling, are still based on a single-sided battery swapping architecture design and do not overcome the limitations of single-sided power supply. Patent CN221917312U, on the "Quick-Change Device for Battery Modules of an Electric Stacker," only optimizes the installation, positioning, and replacement operation of single-sided battery modules, without addressing the high-voltage system design for dual-sided battery swapping. These existing technologies only support single-sided battery pack swapping, failing to solve the problems of short operating range and machine shutdown after a failure caused by single-sided battery swapping, and thus cannot meet the high-intensity, continuous operation requirements of ports. Utility Model Content

[0004] To address the shortcomings of existing electric stacker systems, such as insufficient battery life on one side and the inability of the entire machine to operate after a single-side battery failure, this invention provides a dual-side battery-swapping high-voltage electrical system for electric stackers of empty containers. By designing dual-side interchangeable high-voltage battery packs, the system increases the overall power capacity of the machine. Combined with a high-voltage switching box, it enables rapid switching of power between the two sides. At the same time, it optimizes the charging method, ultimately solving the problems of equipment range anxiety and fault redundancy.

[0005] This utility model is achieved through the following technical solution: a dual-sided battery swapping high-voltage electrical system for an electric stacker for empty containers, characterized in that it includes a dual-sided interchangeable high-voltage battery pack system for providing high-voltage power, a battery swapping connector for bridging power transmission, a high-voltage switching box for controlling the switching of dual-sided high-voltage power, a high-voltage distribution box for distributing high-voltage power to the load, and an execution load module, a power conversion module, and a temperature control module connected to the high-voltage distribution box, and also includes a chassis dual-sided charging base for charging dual-sided batteries; The dual-side interchangeable high-voltage battery pack system is equipped with a high-voltage junction box, which is connected to a battery management unit for controlling power output and a heat dissipation unit for regulating battery temperature. The dual-side interchangeable high-voltage battery pack system also has its own independent charging interface. The two ends of the battery swapping connector are respectively connected to the high-voltage junction box and the chassis high-voltage system, realizing the power input and output docking between the dual-side interchangeable high-voltage battery pack system and the chassis high-voltage system.

[0006] The high-voltage switching box is equipped with a switching component for controlling the on / off state of the dual high-voltage circuits. Its input end forms a multi-channel power input connection with the dual-side power exchange connectors, and its output end forms a power output connection with the high-voltage distribution box. The switching component's on / off action enables the selective or on-demand switching output of dual-side high-voltage power.

[0007] The high-voltage distribution box is equipped with a power distribution component for distributing electrical energy. Its input end is connected to the output end of the high-voltage switching box, and its output end is connected to the execution load module, the power conversion module, and the temperature control module through the power distribution component to form a corresponding power supply connection.

[0008] The dual charging bases on both sides of the chassis are cross-connected to the dual interchangeable high-voltage battery pack systems, enabling synchronous charging of the dual interchangeable high-voltage battery pack systems when they are not disassembled, and allowing the dual interchangeable high-voltage battery pack systems to be charged separately through their own independent charging interfaces after disassembly.

[0009] The battery management unit is used to control the high-voltage power output status of the high-voltage junction box, and the heat dissipation unit is used to adjust the operating temperature of the dual-sided interchangeable high-voltage battery pack system. The operation of the heat dissipation unit is controlled by the battery management unit.

[0010] The switching components inside the high-voltage switching box include at least two sets of high-voltage relays corresponding to the high-voltage circuits on both sides. By controlling the activation and deactivation of different sets of high-voltage relays, the high-voltage power on the corresponding side is output to the high-voltage distribution box through the high-voltage switching box.

[0011] The execution load module includes a drive execution unit for controlling the movement of the forklift, a lifting execution unit for controlling the movement of the forklift gantry, and an auxiliary execution unit for controlling the movement of the forklift lifting equipment and control system. The drive execution unit, the lifting execution unit, and the auxiliary execution unit are all connected to the main power supply circuit of the power distribution components in the high-voltage distribution box.

[0012] The power conversion module is a low-voltage power conversion unit. Its input end is connected to the conversion power supply circuit of the power distribution components in the high-voltage distribution box, and its output end provides charging power with a preset voltage to the low-voltage system of the forklift.

[0013] The temperature control module includes a compressor unit for cooling and a heating unit for heating, and both the compressor unit and the heating unit are connected to the auxiliary power supply circuit of the power distribution components in the high-voltage distribution box.

[0014] The chassis dual-side charging base includes a chassis left-side charging base and a chassis right-side charging base. The chassis left-side charging base is connected to the right-side battery pack in the dual-side interchangeable high-voltage battery pack system, and the chassis right-side charging base is connected to the left-side battery pack in the dual-side interchangeable high-voltage battery pack system. With the independent charging interface provided by the dual-side interchangeable high-voltage battery pack system, dual-side synchronous charging can be achieved in the non-disassembly state.

[0015] The preset connection form between the battery pack and the high-voltage junction box of the dual-side interchangeable high-voltage battery pack system is a three-series-two-parallel circuit connection.

[0016] The beneficial effects of this utility model are: for the first time, a dual-sided interchangeable high-voltage battery pack system is constructed on an electric stacker, which, combined with a high-voltage switching box, enables on-demand switching of power between the two sides, breaking the limitations of traditional single-sided battery swapping and providing a more flexible power supply solution for the equipment.

[0017] Significantly improves battery life and fault redundancy: The dual-side battery pack design maximizes the total battery capacity of the machine, effectively solving range anxiety; when a single-side battery pack fails, the high-voltage switching box can complete the power switching in milliseconds, realizing the isolation of the faulty battery pack and ensuring continuous operation of the whole machine.

[0018] The battery pack has a built-in independent charging interface, which can be disassembled for separate charging and maintenance, reducing equipment downtime for maintenance. Attached Figure Description

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0020] Figure 1 This is a block diagram of a dual-sided high-voltage battery swapping system; Figure 2 This is a diagram of the high-voltage switching box architecture. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model; the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In addition, unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0023] like Figure 1 and Figure 2 As shown, a dual-sided high-voltage electrical system for an electric stacker for empty containers includes a dual-sided interchangeable high-voltage battery pack system, a battery swapping connector, a high-voltage switching box, a high-voltage distribution box, an execution load module, a power conversion module, a temperature control module, and dual-sided charging bases on the chassis.

[0024] Dual-sided interchangeable high-voltage battery pack system: As the core power supply component, it consists of two identical and interchangeable sides. The battery packs are connected to the high-voltage junction box via a "three series, two parallel" circuit connection to ensure stable power output. The high-voltage junction box is connected to both the Battery Management Unit (BMS) and the Thermal Management System (TMS): The BMS monitors the battery status and controls the high-voltage power output of the junction box, preventing safety risks such as overcharging and over-discharging; the TMS, controlled by the BMS, adjusts the heat dissipation power according to the real-time battery temperature, ensuring the battery operates within a suitable temperature range and extending battery life. Furthermore, both battery packs have independent charging interfaces, allowing for independent charging via external power after disassembly, improving battery maintenance flexibility.

[0025] Battery swapping connector: Acting as a "power transmission bridge," one end is fixedly connected to the high-voltage junction box, while the other end is pluggable and interfaces with the chassis high-voltage system. When replacing the battery pack, simply disconnect the old battery pack's battery swapping connector and connect the new battery pack's connector to quickly establish a power connection between the battery pack and the chassis high-voltage system. The operation is simple and highly safe.

[0026] High-voltage switching box: The core control component for dual-sided power switching, it contains two sets of high-voltage relays corresponding to the high-voltage circuits on the left and right sides (K1 and K2 relays on the left, and K3 and K4 relays on the right). Its input terminals are designed with four paths, connecting to the positive and negative high-voltage lines of the battery swapping connectors on the left and right sides respectively; the output terminals are two paths, directly connecting to the input terminals of the high-voltage distribution box. When power from the left battery pack is needed, the battery management unit sends a signal to control relays K1 and K2 to engage and relays K3 and K4 to disengage. High-voltage power from the left battery pack flows into the high-voltage distribution box through the battery swapping connector and relays K1 and K2. When the left battery pack malfunctions or has insufficient power, the battery management unit immediately switches the control logic, disengaging relays K1 and K2 and engaging relays K3 and K4, seamlessly switching power to the right battery pack. The entire switching process requires no downtime, ensuring continuous operation.

[0027] High-voltage distribution box: As the central hub for power distribution, it contains power distribution components such as main positive relay, DC-DC relay, and auxiliary relay. The input end is connected to the output end of the high-voltage switching box, and the output end realizes the classification and distribution of power through different power distribution components: the output end of the main positive relay is connected to the load module to provide power for equipment operation; the output end of the DC-DC relay is connected to the power conversion module to realize the conversion of high-voltage power to low-voltage power; the output end of the auxiliary relay is connected to the temperature control module to meet the temperature control requirements of the equipment.

[0028] The execution load module includes a drive execution unit (drive motor), a lifting execution unit (lifting motor), and an auxiliary execution unit (auxiliary motor), all of which are connected to the output terminal of the main positive relay in the high-voltage distribution box. The drive execution unit controls the travel of the forklift, the lifting execution unit controls the lifting and lowering of the gantry, and the auxiliary execution unit controls the grabbing, steering, and braking of the spreader. These three components work together to achieve the core operational functions of the forklift.

[0029] Power conversion module: Specifically, it is a DC-DC module. Its input terminal is connected to the output terminal of the DC-DC relay in the high-voltage distribution box. It can convert high-voltage power into 24V low-voltage power to power the low-voltage system of the forklift (such as instrument panel, control buttons, etc.) and ensure the normal operation of low-voltage equipment.

[0030] Temperature control module: Includes compressor unit and heating unit (PTC), both connected to the output terminals of the accessory relays in the high-voltage distribution box. The compressor unit cools the cockpit when operating, while the heating unit heats the cockpit when operating, meeting driving comfort requirements under different ambient temperatures.

[0031] Dual-sided charging docks on the chassis: These include a charging dock on the left side and a charging dock on the right side of the chassis, employing a "cross-connection" design. The charging dock on the left side connects to the right battery pack, and the charging dock on the right side connects to the left battery pack. When the battery packs are not removed, an external charging device can be connected to either charging dock to simultaneously charge both battery packs via the cross-connection, significantly reducing charging time. If individual battery maintenance is required, it can be removed and charged separately through the battery pack's independent charging interface, balancing charging efficiency and maintenance flexibility.

[0032] When the forklift starts operation, the BMS controls the high-voltage junction box to output high-voltage power. When the battery temperature exceeds the preset threshold, the BMS controls the cooling unit (TMS) to start the fan or coolant circulation to reduce the battery temperature to a suitable range. When the battery pack on one side is below 20% charge, the operator can remove the battery pack and charge it separately through its independent charging interface, while replacing it with a fully charged battery pack, achieving "second-level battery swapping".

[0033] The battery swapping connector features an anti-misfit design. One end is secured to the high-voltage junction box with bolts, while the other end connects to the chassis's high-voltage system interface via a clip. Once connected, it automatically locks in place to prevent detachment during operation. When changing the battery pack, operators simply need to press the unlock button to disconnect the connector, making the operation convenient and highly safe.

[0034] The high-voltage switching box has four input terminals connected to the left and right battery swapping connectors, and two output terminals connected to the high-voltage distribution box. During normal operation, if the left battery pack has sufficient power, the BMS sends a signal to the high-voltage switching box, controlling relays K1 and K2 to engage and relays K3 and K4 to disengage. The high-voltage power from the left battery pack flows into the high-voltage distribution box through the battery swapping connector and relays K1 / K2. When the BMS detects an overvoltage, overcurrent, or abnormal temperature fault in the left battery pack, it immediately sends a switching signal, disengaging relays K1 and K2 and engaging relays K3 and K4, switching power to the right battery pack. The forklift does not need to be stopped, and the continuity of operation is not affected.

[0035] After receiving the high-voltage power output from the high-voltage switching box, the high-voltage distribution box distributes the power according to the load demand: When the main positive relay is closed, the high-voltage power is delivered to the drive motor, lifting motor, and auxiliary motor. The drive motor drives the stacker to move, the lifting motor drives the gantry to lift and lower to move containers, and the auxiliary motor controls the opening and closing of the spreader, the steering of the steering wheels, and the braking of the braking system; When the DC-DC relay is closed, the high-voltage power enters the DC-DC module and is converted into 24V low-voltage power to power low-voltage equipment such as the instrument panel and control switches; When the accessory relay is closed, the high-voltage power is delivered to the compressor and PTC respectively. In summer, the compressor works to cool the cab, and in winter, the PTC works to heat the cab.

[0036] During charging, if the battery pack is not removed, connect the charging gun of the external charging station to the charging dock on the left side of the chassis. The current is split into two paths through the charging dock on the left side of the chassis: one path flows directly into the left battery pack (through the charging interface of the left battery pack), and the other path flows into the right battery pack (through the connection line between the charging dock on the left side of the chassis and the right battery pack), so that the two battery packs are charged simultaneously. Similarly, connecting the charging dock on the right side of the chassis can also achieve simultaneous charging on both sides. If the battery needs to be maintained separately, after removing the battery pack, it can be charged separately by connecting an external charger through its independent charging interface, which is more flexible.

[0037] This invention effectively solves the problems of short battery life and downtime after failure in traditional single-sided battery swapping systems through the coordinated design of interchangeable battery packs on both sides and high-voltage switching boxes. At the same time, it optimizes the charging and maintenance process, significantly improving the efficiency and reliability of electric stackers for empty containers in port operations. It has high practical value and promising prospects for promotion.

Claims

1. A double-sided high-voltage electrical system for an empty container electric container lift truck, characterized by, It includes a dual-sided interchangeable high-voltage battery pack system for providing high-voltage power, a battery swapping connector for bridging power transmission, a high-voltage switching box for controlling the switching of dual-sided high-voltage power, a high-voltage distribution box for distributing high-voltage power to the load, and an execution load module, a power conversion module, and a temperature control module connected to the high-voltage distribution box. It also includes a chassis dual-sided charging base for charging dual-sided batteries. The dual-side interchangeable high-voltage battery pack system is equipped with a high-voltage junction box, which is connected to a battery management unit for controlling power output and a heat dissipation unit for regulating battery temperature. The dual-side interchangeable high-voltage battery pack system also has its own independent charging interface. The two ends of the battery swapping connector are respectively connected to the high-voltage junction box and the chassis high-voltage system, realizing the power input and output docking between the dual-side interchangeable high-voltage battery pack system and the chassis high-voltage system.

2. The double-sided high-voltage electrical system for electric container lift trucks according to claim 1, characterized in that, The high-voltage switching box is equipped with a switching component for controlling the on / off state of the dual high-voltage circuits. Its input end forms a multi-channel power input connection with the dual-side power exchange connectors, and its output end forms a power output connection with the high-voltage distribution box. The switching component's on / off action enables the selective or on-demand switching output of dual-side high-voltage power.

3. The double-sided high-voltage electrical system for electric container lift trucks according to claim 1, characterized in that, The high-voltage distribution box is equipped with a power distribution component for distributing electrical energy. Its input end is connected to the output end of the high-voltage switching box, and its output end is connected to the execution load module, the power conversion module, and the temperature control module through the power distribution component to form a corresponding power supply connection.

4. The double-sided high-voltage electrical system for electric container lift trucks according to claim 1, characterized in that, The dual charging bases on both sides of the chassis are cross-connected to the dual interchangeable high-voltage battery pack systems, enabling synchronous charging of the dual interchangeable high-voltage battery pack systems when they are not disassembled, and allowing the dual interchangeable high-voltage battery pack systems to be charged separately through their own independent charging interfaces after disassembly.

5. The dual side battery swap high voltage electrical system for an empty container handler electric lift truck of claim 1, wherein, The battery management unit is used to control the high-voltage power output status of the high-voltage junction box, and the heat dissipation unit is used to adjust the operating temperature of the dual-sided interchangeable high-voltage battery pack system. The operation of the heat dissipation unit is controlled by the battery management unit.

6. The dual side battery swap high voltage electrical system for an empty container handler electric lift truck of claim 1, wherein, The switching components inside the high-voltage switching box include at least two sets of high-voltage relays corresponding to the high-voltage circuits on both sides. By controlling the activation and deactivation of different sets of high-voltage relays, the high-voltage power on the corresponding side is output to the high-voltage distribution box through the high-voltage switching box.

7. The dual-sided power swapping high-voltage electrical system for an electric stacker for empty containers according to claim 1, characterized in that, The execution load module includes a drive execution unit for controlling the movement of the forklift, a lifting execution unit for controlling the movement of the forklift gantry, and an auxiliary execution unit for controlling the movement of the forklift lifting equipment and control system. The drive execution unit, the lifting execution unit, and the auxiliary execution unit are all connected to the main power supply circuit of the power distribution components in the high-voltage distribution box.

8. The dual side battery swap high voltage electrical system for an empty container container electric lift truck of claim 1, wherein, The power conversion module is a low-voltage power conversion unit. Its input end is connected to the conversion power supply circuit of the power distribution components in the high-voltage distribution box, and its output end provides charging power with a preset voltage to the low-voltage system of the forklift.

9. The dual side battery swap high voltage electrical system for an empty container container electric lift truck of claim 1, wherein, The temperature control module includes a compressor unit for cooling and a heating unit for heating, and both the compressor unit and the heating unit are connected to the auxiliary power supply circuit of the power distribution components in the high-voltage distribution box.

10. The dual side battery swap high voltage electrical system for an empty container container electric lift truck of claim 1, wherein, The chassis dual-side charging base includes a chassis left-side charging base and a chassis right-side charging base. The chassis left-side charging base is connected to the right-side battery pack in the dual-side interchangeable high-voltage battery pack system, and the chassis right-side charging base is connected to the left-side battery pack in the dual-side interchangeable high-voltage battery pack system. With the independent charging interface of the dual-side interchangeable high-voltage battery pack system, synchronous charging on both sides can be achieved when the batteries are not disassembled. The preset connection form between the battery packs of the dual-side interchangeable high-voltage battery pack system and the high-voltage junction box is a three-series and two-parallel circuit connection form.

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