Swappable Vehicle Battery Alignment With Horizontal Guide Recesses
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Solution Overview
Problem
Existing electric vehicle battery swapping systems face challenges due to the heavy and complex nature of swappable batteries, requiring precise positioning and multiple operators for connection, which can lead to damage and increased downtime.
Innovation Solution
A system featuring a battery enclosure and receptacle with horizontal guides and recesses that facilitate easy alignment and secure positioning, allowing for efficient battery swapping without manual adjustments, reducing the need for multiple operators and minimizing damage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vertically-oriented guiding elements are used for battery placement, then precise vertical movement of the battery is achieved, but the system limits options for battery placement and removal and requires precise positioning that may damage guide elements or vehicle chassis
Solution Approach 1:
The patent inverts the conventional vertical guiding approach by implementing horizontally-extending guides that protrude from the support structure. Instead of guiding the battery vertically during placement, the horizontal guides allow the battery to be positioned horizontally and then lowered vertically onto the support structure, fundamentally changing the sequence and direction of guiding operations
Solution Approach 2:
The patent transitions from a single vertical dimension of guidance to a two-dimensional approach by adding horizontal guidance elements. The horizontal guides extend perpendicular to the vertical direction, creating a composite guidance system that operates in both horizontal and vertical dimensions, thereby expanding placement options while maintaining precision
2Manufacturing precision
If puck-shaped protrusions are added to battery sidewalls for vertical guiding engagement, then vertical guidance is achieved, but the protrusions can damage the vertical guide elements or vehicle chassis
Solution Approach 1:
The patent extracts the problematic puck-shaped protrusions from the battery design and replaces them with recesses formed directly in the battery bottom surface. This extraction eliminates the protruding elements that cause damage while maintaining the guidance function through the recess-groove interface
Solution Approach 2:
The patent introduces horizontal guides as intermediary elements between the battery and the support structure. These guides engage with recesses in the battery bottom rather than protrusions on the sides, serving as a protective intermediary that prevents direct contact and potential damage between the battery and vertical guide elements or chassis
3Manufacturing precision
If multiple operators are used to manually position and connect the battery, then precise positioning is achieved, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent implements a self-aligning system where the horizontal guides and recesses automatically guide the battery into the correct position during the lowering operation. The geometry of the guides and recesses provides self-correcting alignment, eliminating the need for multiple operators to manually position and adjust the battery, while still achieving precise positioning
Data Source
AI summary
A system for aligning a removable battery for a vehicle includes a battery enclosure and a battery receptacle formed on the vehicle, the battery receptacle defined by a first sidewall, a second sidewall, and a support structure. The system also includes a first horizontally-extending guide, a second horizontally-extending guide, a first recess configured to guide the battery enclosure with the first horizontally-extending guide, and a second recess configured to guide the battery enclosure with the second horizontally-extending guide.