Modular Battery Interface Plate for Rapid EV Battery Swapping
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Solution Overview
Problem
Current electric vehicle battery technology limits range and requires lengthy charging times, making it inconvenient for users and restricting long trips 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 using motors, controllers, and alignment pegs for precise positioning, along with a robot-assisted system for automated battery exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual plugging of power supply line is used for charging, then charging operation can be performed, but convenience for vehicle operator deteriorates and charging instances may be missed
Solution Approach 1:
The charging system performs automatic connection and charging initiation without requiring manual operator intervention. The vehicle autonomously connects to the power supply line and starts charging based on detected conditions, eliminating the need for manual plugging and preventing missed charging opportunities.
2Quantity of substance
If electro-chemical rechargeable batteries are used, then energy storage can be achieved, but energy density is insufficient compared to chemical sources
Solution Approach 1:
The battery system is divided into multiple modular battery packs that can be individually replaced. Each pack contains electro-chemical batteries, but the modular architecture allows carrying multiple packs to achieve higher total energy capacity, effectively increasing the energy available per vehicle weight by swapping packs rather than relying on a single large-capacity battery.
3Loss of time
If battery swapping system is implemented, then charging time is reduced, but device complexity increases due to interface plate and battery tray mechanisms
Solution Approach 1:
The battery system is segmented into modular packs with standardized interfaces. Each battery pack is a self-contained unit that can be independently handled and swapped. This segmentation simplifies the swapping mechanism by reducing it to basic mechanical insertion and extraction actions, rather than requiring complex disassembly or reconfiguration systems.
Solution Approach 2:
The interface plate and battery tray are designed as universal components that work with all battery packs in the system. The standardized mechanical and electrical interfaces allow the same swapping mechanism to handle different battery configurations, reducing overall system complexity through component reuse and standardization.
4Length of moving object
If multiple battery packs are carried for extended range, then vehicle range is increased, but weight of vehicle increases
Solution Approach 1:
The battery system transitions from a static fixed installation to a dynamic modular configuration. Battery packs can be added or removed based on trip requirements, allowing the vehicle to optimize its weight for each journey. For short trips, fewer packs are carried; for long trips, additional packs are attached, making the weight adaptable to the actual energy needs.
Data Source
AI summary
An apparatus for electrically and mechanically coupling battery modules to an electric vehicle includes an interface plate and one or more battery trays. The interface plate includes an electrical output that electrically couples the interface plate to the vehicle. The interface plate also includes an electrical input that is electrically coupled to the electrical output. The battery tray is configured to receive a plurality of replaceable battery modules and is releasably mechanically coupled to the interface plate.