EV Battery Pack Ramp Swapping Without Robotic Infrastructure
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Solution Overview
Problem
Existing battery pack-swapping installations for electric and hybrid-electric vehicles are costly, lack speed, and require extensive infrastructure and a power source, making them inefficient for quick battery replacement.
Innovation Solution
A battery pack replacement system that includes a replacement pack ramp, a vehicle-mountable battery pack receptacle, and a vehicle-mountable replacement pack coupling system, allowing for autonomous connection and loading of a new battery pack while the vehicle is in motion, without the need for robotics or external power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If robotic facilities are used for battery pack swapping, then automation is improved, but device complexity and capital infrastructure requirements increase
Solution Approach 1:
The vehicle performs the battery swapping operation itself by driving up the ramp and using its own motion to load the replacement pack, eliminating the need for external robotic facilities. The vehicle's propulsion system provides the force needed to pull the replacement pack up the ramp and into the receptacle, making the system self-sufficient without complex external automation infrastructure.
2Extent of automation
If robotic facilities are used for battery pack swapping, then automation is improved, but capital infrastructure requirements increase
Solution Approach 1:
The vehicle uses its own propulsion system to perform the battery swapping operation, eliminating the need for expensive external robotic facilities and complex capital infrastructure. The ramp structure is simple and passive, requiring no powered mechanisms, while the vehicle's existing motor and drivetrain provide all necessary force for the swapping operation.
Solution Approach 2:
The patent replaces complex mechanical robotic systems with a simple inclined plane (ramp) structure. Instead of using powered robotic arms or conveyors to move the battery pack, the system uses gravity and the vehicle's motion to load the replacement pack, significantly reducing mechanical complexity and infrastructure requirements.
3Productivity
If traditional battery swapping methods are used, then battery replacement is achieved, but speed is reduced
Solution Approach 1:
The battery swapping operation is performed continuously as the vehicle drives up the ramp without interruption. The coupling system engages the replacement pack during the vehicle's upward motion, and the vehicle's continuous propulsion force loads the pack into the receptacle in a single uninterrupted action, minimizing the time the vehicle is non-operational.
Solution Approach 2:
The system uses the vehicle's dynamic motion to perform the swapping operation. Instead of static robotic manipulation, the replacement pack is loaded while the vehicle is moving up the ramp, utilizing the vehicle's kinetic energy and motion to facilitate the swapping process, thereby reducing the time required for battery replacement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and rapid replacement of depleted battery packs with new ones, reducing the need for extensive infrastructure and power sources, and allowing vehicles to continue operation with minimal downtime.
Implementation Method 1
the ramp being structured so that movement of the replacement pack up the ramp causes the replacement pack to be positioned in in the receptacle
Data Source
AI summary
An electric vehicle (EV) battery pack replacement system includes a replacement pack ramp structure having a replacement pack ramp, a vehicle-mountable battery pack receptacle, and a vehicle-mountable replacement pack coupling system structured to be operable to connect a vehicle to a replacement pack positioned on the ramp during movement of the vehicle over the ramp. Further movement of the vehicle over the ramp after connection to the replacement pack to the vehicle moves the replacement pack up the ramp. The ramp is structured so that movement of the replacement pack up the ramp causes the replacement pack to be positioned in in the receptacle. The system uses continuous motion of the vehicle and the replacement pack coupling system for loading a new battery, obviating the need for robotics or other active or powered infrastructure external to the vehicle.