Modular Battery Interface Plate for Fast EV Battery Swapping
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Solution Overview
Problem
Current electric vehicle battery technology limits range and requires lengthy charging times, making long trips impractical due to the lack of ubiquitous charging infrastructure and inefficient battery swapping processes.
Innovation Solution
A modular battery system with an interface plate and battery trays that allow for easy mechanical and electrical coupling to a vehicle, enabling quick swapping of battery modules without the need for prolonged charging, utilizing a robot-assisted system for efficient battery exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual battery charging is used, then the vehicle operator can recharge the energy storage system, but the operator must manually plug the power supply line which is inconvenient and results in missed charging instances
Solution Approach 1:
The system enables self-service charging through automated detection and connection. The vehicle system automatically detects the presence of a power supply line and initiates charging without requiring manual plugging by the operator. The controller monitors charging status and manages the entire charging process autonomously, eliminating the need for operator intervention while ensuring charging occurs timely.
2Object-generated harmful factors
If electro-chemical rechargeable batteries are used, then clean technology is achieved, but the energy density is only 1/100th of chemical sources resulting in limited range of about 70 miles
Solution Approach 1:
The battery system is divided into modular units that can be independently replaced. Instead of relying on a single large battery pack with limited capacity, the system uses multiple smaller battery modules that can be individually swapped out. This allows the vehicle to maintain clean electric propulsion while extending operational range by replacing depleted modules with charged ones at charging stations.
Solution Approach 2:
The system changes the operational parameter from fixed battery capacity to dynamic battery replacement. By implementing a modular battery architecture with standardized interfaces, the effective energy capacity of the vehicle becomes variable depending on how many charged modules are available for replacement, thereby extending range without compromising the environmental benefits of electric propulsion.
3Adaptability or versatility
If batteries are recharged in place, then the vehicle can be recharged at any location, but the recharging process takes many hours and may need to be done overnight
Solution Approach 1:
The system performs preliminary charging actions at dedicated charging stations before the vehicle needs to operate. Battery modules are charged in advance at stationary charging locations with higher power capacity, then installed in the vehicle when needed. This separates the charging function from the operating function, allowing rapid module replacement during vehicle use while bulk charging occurs beforehand at appropriate facilities.
4Length of moving object
If battery technology is advanced to provide higher energy density, then the cost of new vehicles increases as batteries contribute 40% to the cost
Solution Approach 1:
The battery system is segmented into standardized modular units that can be manufactured independently and assembled in various configurations. This modularity enables economies of scale in manufacturing individual modules, reducing per-unit costs. The standardized interfaces allow different numbers of modules to be used based on range requirements, letting consumers pay only for the capacity they need while benefiting from mass-produced component costs.
Data Source
AI summary
An apparatus for electrically and mechanically coupling removeable battery modules to a vehicle. The apparatus comprises an interface plate that comprises an electrical output that electrically couples the interface plate to the vehicle; and an electrical input electrically coupled to the electrical output. A gasket is attached to an exposed surface of the interface plate. The apparatus further comprises battery trays that releasably receive the removeable battery modules. Each battery tray is releasably mechanically coupled to the interface plate and comprises at least one battery module connector releasably electrically coupled to a respective at least one battery module; an electrical output that electrically couples the respective battery module connector(s) to the interface plate electrical input; and an outer tray wall extending along a perimeter of the battery tray, the outer tray wall including a flange that is configured to compress the gasket to form a seal.