Battery Pack Turnover Mechanism for Compact Swapping Stations
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Solution Overview
Problem
The existing battery swapping devices for electric vehicles require large spaces due to the need for horizontal rotation of battery packs, leading to complex structures and increased costs, which hinders mass production and market acceptance.
Innovation Solution
A battery swapping device with a turnover mechanism that rotates battery packs 90 degrees, allowing for efficient transfer between electric vehicles and charging bins, reducing the required space and simplifying the structure while enabling the use of single large battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plane-rotation is used to rotate battery pack, then battery pack orientation can be changed, but the required space becomes very large and structure becomes complicated
Solution Approach 1:
The patent changes the rotation dimension from horizontal plane-rotation to vertical axis rotation. The turnover mechanism rotates the battery pack around a vertical axis, transforming the rotation from a two-dimensional horizontal movement to a three-dimensional vertical operation, thereby reducing the horizontal space requirement.
Solution Approach 2:
Instead of rotating the battery pack horizontally in the conventional manner, the patent inverts the rotation approach by using a vertical axis rotation mechanism. The battery pack is rotated upright around a vertical axis rather than being flipped horizontally, which fundamentally changes the space requirements.
2Ease of operation
If plane-rotation is used to rotate battery pack, then battery pack orientation can be changed, but the structure becomes complicated and manufacturing difficulty increases
Solution Approach 1:
The patent inverts the conventional rotation mechanism by using a vertical axis turnover mechanism instead of horizontal plane-rotation. This inversion simplifies the mechanical structure by eliminating the need for complex horizontal rotation joints and associated control systems.
Solution Approach 2:
The turnover mechanism is divided into separate functional components: a turnover mechanism body, a turnover mechanism driver, and a turnover mechanism transmitter. This segmentation allows for simpler individual components that are easier to manufacture and assemble, reducing overall device complexity.
3Productivity
If dual side battery swapping is used, then battery swapping can be implemented, but the occupied area of battery swapping station increases
Solution Approach 1:
The patent utilizes vertical space by implementing rotation around a vertical axis, allowing the battery swapping operation to occur within a more compact horizontal footprint. The vertical dimension is leveraged to achieve the necessary orientation changes without expanding the horizontal station area.
Solution Approach 2:
The turnover mechanism serves multiple functions: it rotates the battery pack, positions it for charging, and enables dual-side swapping operations. This multi-functionality allows the system to achieve comprehensive battery swapping capability while maintaining a compact station footprint.
Data Source
AI summary
Disclosed are a battery swapping device, a battery swapping station and a battery swapping method. The battery swapping device comprises a turnover mechanism for turning a used battery pack taken out of an electric vehicle from a first position to a second position in a first direction; or turning a fresh battery pack taken out of a battery charging bin from a third position to a fourth position in a second direction, the first direction being opposite to the second direction. The present invention occupies less space for turnover, and can be significantly reduced with respect to a plane-rotating battery swapping device in structure. Thus, it can complete picking and placing of larger battery packs with a smaller space and structure. Therefore, battery swapping with a single large battery pack can be realized in a smaller area, thereby reducing the cost of the battery pack and facilitating promotion.