Interchangeable battery carrier, method for its insertion and locking in a vehicle and vehicle with battery mounting area

Abstract

Interchangeable battery carrier (100) for an electrically powered vehicle, wherein the interchangeable battery carrier (100) comprises: a longitudinal beam element (102) with an outer side (1041) and an inner side (1042) extending along a first direction (x); a gripping means (106) on the outside (1041) of the longitudinal support element (102), wherein the interchangeable battery carrier (100) can be inserted horizontally into a battery receiving area of ​​the electrically powered vehicle by the gripping means (106), removed and thereby completely separated from the electrically powered vehicle; at least two crossbeam elements (108) which are each connected on the inside (1042) to the longitudinal beam element (102) and extend parallel to each other along a second direction (y), wherein a battery module (110) can be accommodated between two adjacent crossbeam elements (108); a plurality of locking means (112) for locking the interchangeable battery carrier (100) in the battery receiving area of ​​the electrically powered vehicle, wherein the plurality of locking means (112) are each movable between a first position and a second position, and wherein a part of the locking means (112) is formed on a top (120, 124) and / or a bottom (122, 126) of the longitudinal member element (102), and the other part of the plurality of locking means (112) is formed on a top (120, 124) and / or a bottom (122, 126) of the plurality of cross member elements (108).

Description

TECHNICAL AREA

[0001] The present invention relates to an interchangeable battery carrier for an electrically powered vehicle, a method for inserting and locking an interchangeable battery carrier into a battery receiving area of ​​an electrically powered vehicle, and an electrically powered vehicle with a battery receiving area. BACKGROUND

[0002] Rechargeable batteries are used in a wide variety of devices for power supply because they can be repeatedly charged and discharged. Depending on the application, rechargeable batteries or accumulators with low capacity are used for small electronic devices such as digital cameras, mobile phones, laptops, or smartwatches, while high-capacity rechargeable batteries are used to power vehicles, such as road vehicles. A rechargeable battery uses one or more battery modules. A battery module consists of several individual cells connected in series and / or parallel, depending on the required capacity.

[0003] The mechanical integration of the battery module(s) is achieved by attaching the battery module(s) to the interchangeable battery tray, e.g., by screwing them in. The interchangeable battery tray is then fixed in a final position within a battery mounting area of ​​the electrically powered vehicle. Exemplary battery exchange devices are described in the publications US 2019 / 0 118 782 A1, FR 2 942 997 A1, US 2012 / 0 326 107 A1, DE 10 2009 052 525 A1, and EP 2 779 274 A1.

[0004] Numerous requirements are placed on the changing and securing of the interchangeable battery tray. For example, it is desirable that the interchangeable battery tray can be changed quickly, such as when changing the battery tray during a race with an electrically powered motorsport vehicle. It is also desirable that the interchangeable battery tray be securely fixed, considering the forces involved in a crash and the danger posed by the weight of the battery modules themselves.

[0005] The invention is based on the objective of providing an improved interchangeable battery carrier as well as a method for inserting and locking an interchangeable battery carrier into a battery receiving area of ​​an electrically powered vehicle and an electrically powered vehicle with a battery receiving area. SUMMARY

[0006] The invention is defined in the independent patent claims. Further developments are the subject of the dependent patent claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The accompanying figures illustrate exemplary implementations. The figures are exemplary with regard to the structural elements depicted, and structural elements in one figure can be combined with structural elements in another figure. Fig. 1A and Fig. Figure 1B shows schematic views of a replaceable battery holder. Fig. Figure 2 is a schematic cross-sectional view of an exemplary longitudinal support element of the interchangeable battery carrier. Fig. 3A and Fig. Figure 3B shows schematic cross-sectional views of an exemplary crossbeam element of the interchangeable battery carrier. Fig. Figure 4 shows a schematic cross-sectional view of an electrically powered vehicle with a battery mounting area. DETAILED DESCRIPTION

[0008] The following detailed description refers to the accompanying drawings, which illustrate specific embodiments. The drawings are not to scale and serve only for illustrative purposes. For example, the figures may only show parts of structural elements, such as a section of the push rod, to describe a function based on the depicted part. Corresponding elements are designated by the same reference symbols in the various drawings unless otherwise stated.

[0009] The terms "have," "contain," "comprise," "exhibit," and similar terms are open-ended, indicating the presence of the identified structures, elements, or features, but not excluding the presence of additional elements or features. Indefinite and definite articles should encompass both the plural and singular unless the context clearly indicates otherwise.

[0010] One embodiment relates to an exchangeable battery carrier for an electrically powered vehicle. The electrically powered vehicle can be partially or fully electric. For example, a partially electric vehicle could be a hybrid electric vehicle. The electrically powered vehicle could also be an electrically powered watercraft, such as an electrically powered displacement hull or a power glider. Similarly, the electrically powered vehicle could be an electrically powered land vehicle, such as a rail vehicle, a road vehicle, or an all-terrain vehicle. Finally, the electrically powered vehicle could be an electrically powered aircraft, such as a helicopter.

[0011] The interchangeable battery carrier can have a longitudinal member element with an outer and an inner side extending along a first direction. The interchangeable battery carrier can have a gripping means on the outer side of the longitudinal member element, wherein the interchangeable battery carrier can be inserted horizontally into and removed from a battery receiving area, e.g., a battery receiving compartment or a battery slot, of the electrically powered vehicle by means of the gripping means. The outer side of the longitudinal member element is the side that, after insertion of the interchangeable battery carrier into the battery receiving area, faces outwards with respect to the interior of the vehicle.The extent of a longitudinal member in a horizontal plane can be defined, for example, by its width and depth. The width of the longitudinal member can be determined by its extent along the first direction, and the depth of the longitudinal member can be defined by its extent perpendicular to the first direction in the horizontal plane. A vertical extent of the longitudinal member can be defined as its height in a direction perpendicular to the horizontal plane. For example, the depth of the longitudinal member is less than both its width and its height. The battery mounting area of ​​an electrically powered vehicle can, for example, be a battery mounting compartment or a battery mounting box, which may be provided as part of the vehicle body.The gripping element can, for example, be a shaped feature on the outside of the interchangeable battery carrier, allowing a robot gripper arm to grasp the carrier and transport it, for instance, for battery replacement. The gripping element may have suitable recesses on the outside of the longitudinal support element or projections, such as handles. The gripping element can therefore be shaped outwards and / or inwards with respect to the outside of the longitudinal support element.

[0012] The interchangeable battery carrier can further comprise at least two crossbeam elements, each connected to the longitudinal beam element on its inner side and extending parallel to each other along a second direction. This second direction can, for example, be a depth direction of the longitudinal beam element. The second direction can be perpendicular to the first direction. A battery module can be accommodated between two adjacent crossbeam elements. The battery module can be fixed to the interchangeable battery carrier, e.g., to the adjacent crossbeam elements and / or the longitudinal beam element, e.g., by screws.

[0013] The interchangeable battery carrier can further comprise a plurality of locking devices for securing the interchangeable battery carrier in the battery mounting area of ​​the electrically powered vehicle. Each of these multiple locking devices can be movable between a first position and a second position.

[0014] For example, the interchangeable battery carrier further comprises at least one drive element that is mechanically coupled to at least some of the multiple locking elements and, when force is applied to the drive element, causes movement of at least some of the multiple locking elements. A drive element can be mechanically coupled to one or more locking elements. The interchangeable battery carrier can have different drive elements with regard to their function. For example, a force applied to the drive element can be hydraulic, pneumatic, or electrical.

[0015] For example, at least one drive element can cause movement of a mechanically coupled locking device with one or two drive elements, which are movable relative to the coupled locking device by applying force to the at least one drive element. A small number of drive elements improves the reliability and thus the safe operation of the interchangeable battery carrier.

[0016] For example, the multiple locking devices can have at least one bolt, and the bolt can be located within the longitudinal member element or within the cross member element in the first position, and protrude at least partially from the longitudinal member element or the cross member element in the second position. In the second position, the bolts can, for example, provide a horizontal locking action, e.g., an xy locking action. The geometry of the bolt effective for locking the interchangeable battery carrier in the vehicle can have a polygonal or round cross-section. Bolts of different geometries can also be used, for example.

[0017] For example, the bolt can be driven by applying force to a push rod as the first drive element. The push rod can be mechanically coupled to the bolt via a coupling element as the second drive element. Thus, the bolt can be driven with just two drive elements that move differently relative to the bolt. The push rod can, for example, terminate in a piston that is pneumatically, hydraulically, or electrically driven. In this way, the push rod can move along the first direction within the longitudinal beam element or along the second direction within one of the crossbeam elements.

[0018] The interchangeable battery carrier can, for example, have a pneumatic connection and / or a hydraulic connection and / or a connection for electrical power supply and / or a connection for mechanical force supply on the outside of the longitudinal beam element. Via this connection, all or some of the locking mechanisms can be moved by the drive mechanism to lock the interchangeable battery carrier in place. A mechanical force supply can be applied, for example, translationally, e.g., via a rod, or rotationally, e.g., via a gear, on the outside of the longitudinal beam element.

[0019] For example, the multiple locking devices have at least one hook, and the hook is arranged within the longitudinal beam element or within the crossbeam element in the first position and protrudes at least partially from the longitudinal beam element or the crossbeam element in the second position. In the second position, the hook can, for example, effect a vertical locking, e.g., a z-lock.

[0020] By locking the interchangeable battery carrier in the x, y and z directions using different locking devices, a secure locking of the interchangeable battery carrier within the vehicle can be achieved, so that even extreme forces, such as inertial forces in the event of a crash, can be safely absorbed.

[0021] For example, the hook can be designed as a gear at one end, or partially as a gear. A rotational movement of the gear allows the hook to be moved between the first and second positions, thus locking the interchangeable battery holder in place.

[0022] For example, the hook is driven by applying force to a rack as the drive element. The rack can be movable back and forth along the first direction within the longitudinal beam element, or along the second direction within one of the crossbeam elements. Thus, the hook can be driven with just one drive element that moves differently relative to the hook. This allows for a simple and, given the limited number of locking elements, secure and reliable locking of the interchangeable battery holder.

[0023] For example, in the first position of the hook, the rack protrudes from a crossmember and, when inserted into the battery mounting area of ​​the electric vehicle, abuts a part of the vehicle, such as a body panel, before reaching its final position. The rack is then moved relative to the crossmember in the second direction, thereby transferring the hook from the first to the second position. This locking mechanism thus constitutes a self-locking mechanism for the removable battery carrier. The resulting vertical locking of the removable battery carrier can be combined with a further xy-locking mechanism, for example, using bolts in the longitudinal member.

[0024] For example, the crossbeam has a plurality of bolts, and the at least two crossbeam elements each have at least one hook. With this exemplary arrangement of different locking devices, an xy-locking connection on the longitudinal beam can be achieved via the bolts, and a z-locking connection can be achieved via the hooks on the crossbeams.

[0025] In addition to the bolts and hooks described as examples, any other locking devices suitable for securing the interchangeable battery holder can be used additionally or alternatively, e.g. screws.

[0026] For example, the plurality of locking means on a top and / or a bottom, i.e. at least on one side consisting of a top and a bottom, can be formed by at least one element from the longitudinal beam element and the plurality of crossbeam elements.

[0027] For example, a drive mechanism on the outside of the longitudinal beam can be actuated to release a locking device for removing the interchangeable battery holder. This drive mechanism could, for instance, be a rack and pinion system that drives hooks in a crossbeam element.

[0028] For example, the battery tray has a coolant line inside the longitudinal member. The battery tray may also have coolant connections, such as inlet and outlet, on the inside of the longitudinal member. These coolant connections allow, for example, a connection to the vehicle, provided the battery tray is in its final position.

[0029] For example, the interchangeable battery carrier can have media and / or energy connections on the outside of the longitudinal support element, which can provide support during the battery replacement process, e.g., visually and / or acoustically.

[0030] One embodiment relates to a method for inserting and locking a removable battery carrier into a battery compartment of an electrically powered vehicle. The method comprises horizontally inserting the removable battery carrier into the battery compartment. During a period of time before the removable battery carrier reaches its end position until it reaches its end position, a first locking element is moved by a first drive element from a first position to a second position to lock the removable battery carrier. Subsequently, a second locking element is moved by a second drive element from a first position to a second position to further lock the removable battery carrier.

[0031] For example, the first locking device is a hook and the second is a bolt. The locking action of the bolt(s) occurs after the locking action of the hook(s). This is because the bolts can only be extended once the final position in the battery compartment is reached. By this time, the self-locking action of the hooks has already taken place.

[0032] Another embodiment relates to an electrically powered vehicle. The electrically powered vehicle has, for example, a body with a battery mounting area into which a replaceable battery carrier according to one of the preceding examples can be inserted and removed horizontally. The body has a plurality of positive-locking counter-measures corresponding to the locking means of the replaceable battery carrier for locking the replaceable battery carrier when the plurality of locking means is inserted into the plurality of corresponding positive-locking counter-measures. The counter-measures can be molded recesses in the body adapted to the locking means, which are, for example, adapted to the external shape of the locking means, e.g., bolts and / or hooks.

[0033] The features of the examples described above can be combined with one another. For example, the several locking devices shown and described can be combined in any way to lock the interchangeable battery holder.

[0034] In the Fig. 1A and Fig. Figure 1B shows schematic views of a swappable battery carrier 100 for an electrically powered vehicle. The swappable battery carrier 100 has a longitudinal support element 102 with an outer surface 1041 and an inner surface 1042. The longitudinal support element 102 extends along a first direction x.

[0035] The interchangeable battery carrier 100 further features handles 1061 on the outer surface 1041 of the longitudinal support element 102, serving as gripping means 106. The interchangeable battery carrier 100 can be inserted horizontally into and removed from a battery compartment of an electrically powered vehicle by means of the handles 1061. One or more connections 107, e.g., pneumatic, hydraulic, and / or power supply connections, can be integrated into the handles 1061.

[0036] The interchangeable battery carrier 100 further comprises several crossbeam elements 108. The crossbeam elements 108 are each connected to the longitudinal beam element 102 on their inner side 1042 and extend parallel to each other along a second direction y. The first direction x and the second direction y define a horizontal plane. A battery module 110 can be accommodated between two adjacent crossbeam elements 108. The number of battery modules shown is exemplary and can vary depending on the application and energy density requirements.

[0037] A plurality of bolts 1121, acting as locking means 112, are arranged on a top surface 120 and a bottom surface 122 of the longitudinal support element 102 for locking the interchangeable battery carrier 100 in the battery mounting area of ​​the electrically powered vehicle. The plurality of bolts 1121 are movable between a first position and a second position, the second position being illustrated in the schematic diagram and corresponding to the locked state of the interchangeable battery carrier 100.

[0038] A plurality of hooks 1122, acting as locking means 112, are arranged on a top surface 124 and a bottom surface 126 of a crossbeam element 102 for locking the interchangeable battery carrier 100 in the battery mounting area of ​​the electrically powered vehicle. In the schematic representation of Fig. 1A, Fig. In Figure 1B, the hooks 1122 are shown for illustrative purposes only on one of the crossbeam elements 108. However, the hooks 1122 can also be arranged on several or all of the crossbeam elements 108. Furthermore, the arrangement of the hooks 1122 on the upper surface 124 and lower surface 126 between the crossbeam elements 108 can vary or be partially or completely identical. Each set of hooks 1122 is movable between a first position and a second position, with the second position, corresponding to the locked state of the interchangeable battery holder 100, being illustrated schematically. A rack 138 for driving the hooks 1122 is also shown schematically.

[0039] A test device 128 is provided on the outer surface 1041 of the longitudinal support element 102. The test device 128 serves for the visual inspection of a successfully performed battery change. For example, the test device can be linked to a drive element of the hooks 1122 and, only when locked in the position, protrude from the longitudinal support element 102 in a manner suitable for inspection.

[0040] With reference to the schematic cross-sectional view of Fig. Section 2 describes an exemplary drive mechanism for the bolts 1121 in the longitudinal beam element 102. The bolts 1121 are driven by a force acting on a push rod 130, for example, by means of a cylinder 1301 connected to the push rod 130. A force is exerted on the cylinder 1301, for example, pneumatically, hydraulically, or electrically, and its translational movement is converted into a movement of the bolts 1121. The cylinder 1301 with the connected push rod 130 acts as a first drive element, which is mechanically coupled to one of the bolts 1121 via a coupling element 132, which serves as a second drive element. By mechanically coupling several coupling elements 132 to the push rod 130, several bolts 1121 can be driven by the same push rod 130. Each bolt 1121 is driven by only two drive elements movable relative to the bolt, namely the push rod 130 and the associated coupling element 132.

[0041] A coolant line 134 can run within the longitudinal support element 102, which is supplied with coolant via coolant connections 1341, 1342, e.g. coolant inlet and coolant outlet.

[0042] With reference to the schematic cross-sectional views of Fig. 3A and Fig. Section 3B describes an exemplary drive mechanism for the hooks 1122 in the crossbeam element 108. Fig. 3A illustrates the first position of hook 1122 in the unlocked state and in the Fig. Figure 3B illustrates the second position of the hook 1122 in the locked state. The hook 1122 is partially designed as a gear 136 at one end.

[0043] The hook 1122 is driven by a force acting on a rack 138 as the drive element. The rack 138 is movable back and forth along the second direction y within the longitudinal beam element 102.

[0044] The rack 138 is located in the Fig. In the first position shown in Figure 3A, the hook 1122 is displaced from the crossbeam element 108 along the second direction y by an amount Δy. Likewise, the test device 128, connected to the rack 138, is arranged within the longitudinal beam element 102.

[0045] When the interchangeable battery carrier 100 is inserted into the battery compartment of the electrically powered vehicle and before reaching its end position, the rack 138 initially abuts a part of the electrically powered vehicle, e.g., a body panel. This causes the rack 138 to move relative to the cross member 108 along the second direction y, and the hook 1122 is thereby moved from the first position to the second position by the mechanical coupling between the hook 1122 and the rack 138, so that the hook 1122 protrudes from the cross member 108 and locks the interchangeable battery carrier 100 in the vehicle, as shown in Fig. Figure 3B is shown. Due to the relative movement between crossbeam element 108 and rack 138, the test device 128 protrudes from the outside 1041 of the longitudinal beam 102 and signals successful insertion of the interchangeable battery carrier 100.

[0046] In the schematic view of the Fig.Figure 4 shows several partial cross-sections of an electrically powered vehicle 200 superimposed. A first cross-section shows a body 202. Another cross-section relates to a battery mounting area 204, into which an interchangeable battery carrier 100 can be horizontally inserted and removed according to one of the preceding examples. The body 202 has a plurality of positive-locking counter-measures 206 corresponding to the locking means 112 of the interchangeable battery carrier 100 for locking the interchangeable battery carrier 100 when the plurality of locking means 112 are inserted into the plurality of corresponding positive-locking counter-measures 206. First positive-locking counter-measures 2061 serve to receive the bolts 1121. Second positive-locking counter-measures 2062 serve to receive the hooks 1122.The positive locking devices 206 are also to be designed in the bodywork 202 in such a way that they correspond to the locking devices 102 arranged on the longitudinal member element 102 and the cross member elements 108.

[0047] Although specific embodiments are illustrated and described here, it is obvious to those skilled in the art that a multitude of alternative and / or equivalent designs can be used for the specific embodiments shown and described without departing from the scope of this disclosure. For example, further embodiments may be based on the embodiments shown or described, with features added or omitted (e.g., testing equipment, connections).

Claims

[1] Interchangeable battery carrier (100) for an electrically powered vehicle, wherein the interchangeable battery carrier (100) comprises: a longitudinal beam element (102) with an outer side (1041) and an inner side (1042) extending along a first direction (x); a gripping means (106) on the outside (1041) of the longitudinal support element (102), wherein the interchangeable battery carrier (100) can be inserted horizontally into a battery receiving area of ​​the electrically powered vehicle by the gripping means (106), removed and thereby completely separated from the electrically powered vehicle; at least two crossbeam elements (108) which are each connected on the inside (1042) to the longitudinal beam element (102) and extend parallel to each other along a second direction (y), wherein a battery module (110) can be accommodated between two adjacent crossbeam elements (108); a plurality of locking means (112) for locking the interchangeable battery carrier (100) in the battery receiving area of ​​the electrically powered vehicle, wherein the plurality of locking means (112) are each movable between a first position and a second position, and wherein a part of the locking means (112) is formed on a top (120, 124) and / or a bottom (122, 126) of the longitudinal member element (102), and the other part of the plurality of locking means (112) is formed on a top (120, 124) and / or a bottom (122, 126) of the plurality of cross member elements (108). [2] Interchangeable battery carrier (100) according to claim 1, further comprising at least one drive means which is mechanically coupled to at least one part of the plurality of locking means (112) and which, when force is applied to the drive means, causes a movement of at least one part of the plurality of locking means (112). [3] Interchangeable battery carrier (100) according to claim 2, wherein the at least one drive means causes a movement of a locking means (112) mechanically coupled thereto with one or with two drive elements which are movable relative to the coupled locking means (112) by force acting on the at least one drive means. [4] Interchangeable battery carrier (100) according to one of the preceding claims, wherein the plurality of locking means (112) have at least one bolt (1121) and the bolt (1121) is arranged in the first position inside the longitudinal support element (102) or inside the cross support element (108) and in the second position protrudes at least partially from the longitudinal support element (102) or from the cross support element (108). [5] Interchangeable battery carrier (100) according to claim 4, wherein the bolt (1121) is driven by force acting on a push rod (130) as the first drive element, the push rod (130) is mechanically coupled to the bolt (1121) via a coupling member (132) as the second drive element, and the push rod (130) is movable along the first direction (x) within the longitudinal support element (102) or is movable along the second direction (y) within one of the cross support elements (108). [6] Battery holder (100) according to claim 5, further comprising a connection (107) on the outside (1041) of the longitudinal support element (102) for driving the push rod (130). [7] Interchangeable battery carrier (100) according to one of the preceding claims, wherein the plurality of locking means (112) have at least one hook (1122) and the hook is arranged in the first position inside the longitudinal support element (102) or inside the cross support element (108) and in the second position protrudes at least partially from the longitudinal support element (102) or from the cross support element (108). [8] Interchangeable battery carrier (100) according to claim 7, wherein the hook (1122) is designed at one end as a gear or partially as a gear (136). [9] Interchangeable battery carrier (100) according to one of the two preceding claims, wherein the hook (1122) is driven by applying force to a rack (138) as the drive element, and the rack (138) is movable along the first direction (x) within the longitudinal beam element (102) or along the second direction (y) within one of the cross beam elements (108). [10] Interchangeable battery carrier (100) according to the preceding claim, wherein the rack (138) in the first position of the hook (1122) extends from a cross member element (108) and, when inserted into the battery receiving area of ​​the electrically powered vehicle, abuts a part of the electrically powered vehicle before reaching an end position, is moved relative to the cross member element (108) along the second direction (y) and thereby the hook (1122) is moved from the first position to the second position. [11] Interchangeable battery carrier (100) according to one of the four preceding claims, wherein the longitudinal member (102) has a plurality of bolts (1121) and the at least two cross member elements (108) each have at least one hook (1122). [12] Method for inserting and locking a replaceable battery carrier (100) into a battery receiving area (204) of an electrically powered vehicle (200), wherein the method comprises: horizontal insertion of the interchangeable battery carrier (100) completely separated from the electrically powered vehicle (200) into the battery receiving area (204), wherein During a period of time before reaching an end position of the interchangeable battery carrier (100) until reaching the end position of the interchangeable battery carrier (100), a first locking means of the interchangeable battery carrier (100) is moved from a first position to a second position by a first drive means for locking the interchangeable battery carrier (100); and thereafter A second locking means of the interchangeable battery carrier (100) is moved from a first position to a second position by a second drive means for further locking of the interchangeable battery carrier. [13] Method according to claim 12, wherein the first locking means is a hook (1122) and the second locking means is a bolt (1121). [14] Electrically powered vehicle (200) comprising: a body (202) with a battery receiving area (204) into which a replaceable battery carrier (100) according to one of claims 1 to 11 can be inserted horizontally and removed, wherein the body (202) has a plurality of positive locking countermeasures (206) corresponding to the locking means (112) of the replaceable battery carrier (100) for locking the replaceable battery carrier (100) by inserting the plurality of locking means (112) into the plurality of corresponding positive locking countermeasures (206).

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