Battery Replacement Robot with Mobile Storage Rack
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Solution Overview
Problem
Current battery replacement systems for electric vehicles are inefficient due to complex control systems, high failure rates, expensive maintenance, long operation times, and limited scalability, as they require multiple robots and mechanisms, leading to increased complexity and reduced efficiency.
Innovation Solution
A battery replacement robot with a mobile storage rack that integrates multiple functions into one unit, featuring a horizontal mobile unit, a bearing unit, and an electric control system, allowing for simultaneous movement and rotation to efficiently replace multiple battery boxes, reducing travel distance and operation time, and improving control accuracy through multi-axis linkage and sensor integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery boxes are delivered at once, then battery replacement efficiency is improved, but the robot has large weight and volume leading to control difficulties
Solution Approach 1:
The battery replacement system divides the battery boxes into multiple groups, with each group containing a specific number of battery boxes. The robot delivers battery boxes in segmented batches rather than all at once, reducing the weight and volume carried at any given time while maintaining overall replacement efficiency through coordinated multi-robot operation.
2Ease of operation
If the robot moves reciprocally between storage rack and vehicle, then battery replacement is achieved, but operation time is prolonged reducing efficiency
Solution Approach 1:
The system pre-positions multiple battery boxes on the mobile storage rack before the replacement operation begins. The robot loads several battery boxes in advance onto the rack, so that during the actual replacement process, battery boxes are already available and do not need to be fetched from distant storage locations, significantly reducing reciprocating travel time.
Solution Approach 2:
The mobile storage rack acts as an intermediary between the fixed battery storage area and the vehicle. It serves as a temporary holding station that reduces the travel distance for the robot by positioning battery boxes closer to the replacement site, thereby reducing the reciprocating motion required and overall operation time.
3Productivity
If various robots and mechanisms cooperate for battery replacement, then replacement capability is achieved, but system complexity increases leading to high failure rate and maintenance cost
Solution Approach 1:
The patent combines the functions of multiple robots and mechanisms into a single integrated battery replacement robot. This robot incorporates battery box gripping, positioning, and installation capabilities along with a mobile storage rack, eliminating the need for multiple separate robots and reducing system complexity while maintaining full replacement capability.
Solution Approach 2:
The battery replacement robot is designed as a universal device that can handle multiple battery box types and work with different vehicle models. It integrates multiple functions including storage, transport, positioning, and installation of battery boxes, making it adaptable to various replacement scenarios without requiring specialized mechanisms for each case.
Data Source
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AI summary
A battery replacement robot (1) with a mobile storage rack and a battery replacement method. The battery replacement robot (1) comprises a mechanical part and an electrical control part. The electrical control part controls a battery replacement device to place, in one step, all battery boxes required by one side of an electric bus (3) that needs battery replacement onto a battery box storage rack (12). A horizontal moving unit (101) moves to a position where a battery needs to be replaced. A battery box replacement device takes down a spent battery box from the electric bus (3); the battery box replacement device rotates towards one side around a Y axis, and raises or lowers the spent battery box so as to put the spent battery on the battery box storage rack (12); then the battery box replacement device takes down a charged battery box from the battery box storage rack (12), rotates to the original position, and installs the battery box in the electric bus (3). This operation is repeated to complete the battery box replacement on the electric bus (3). Battery boxes required by one side of an electric bus are prepared in one step, which avoids long-distance and repeated operations of the battery replacement robot in a large space. The structure is simple, the battery replacement time is reduced, space occupied by a working area is reduced, and the utilization of land resources is effectively improved.