Battery Pack Replacement System with Surge Protection
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Solution Overview
Problem
Electric vehicles face challenges with battery pack replacement, including non-automatic replacement, short circuit combustion, and insufficient burning due to large current issues, which limit their development and efficiency.
Innovation Solution
A battery pack automatic replacement and explosion-proof system controlled by Internet of Things (IoT) on electric vehicle chassis, utilizing robots to replace battery packs and power surge protectors to manage large currents, ensuring safe and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual battery pack replacement is used, then device complexity is reduced, but productivity is lowered and safety risks increase
Solution Approach 1:
The battery replacement system enables self-service operation where the robot automatically performs battery pack removal and installation without human intervention. The system self-regulates through automated detection, positioning, and securing mechanisms, eliminating the need for manual labor while maintaining operational simplicity.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robot system that uses sensors, actuators, and control systems to perform battery replacement. The robot substitutes human hands and tools with automated end-effectors, positioning systems, and electronic control mechanisms.
2Reliability
If traditional power protection is used, then short circuit protection is provided, but burning still occurs due to large current
Solution Approach 1:
The patent implements localized surge protection at multiple critical points in the electrical system. Different SPD devices are strategically placed at the battery pack level, module level, and system level, each providing protection tailored to the specific current characteristics and requirements of that location. This distributed protection approach ensures that large currents are contained and dissipated locally before causing damage.
Solution Approach 2:
The surge protection devices are pre-installed in the electrical system to provide advance protection against potential large current events. The SPD devices are positioned upstream of vulnerable components, creating a protective buffer that absorbs and diverts surge currents before they can reach and damage critical battery components.
3Speed
If fast charging technology is used, then charging speed is improved, but battery life is damaged
Solution Approach 1:
The patent converts the harmful effect of large charging currents into a beneficial protection mechanism. The surge protection devices are designed to handle and dissipate the high currents associated with fast charging, transforming what would be damaging surge events into controlled energy dissipation. This allows the system to accept fast charging input while protecting the battery from the harmful effects of current surges.
4Loss of time
If battery pack replacement is not automated, then device complexity is reduced, but loss of time increases
Solution Approach 1:
The robot system performs preliminary actions to prepare for battery replacement before it is needed. The system includes pre-programmed replacement sequences, pre-positioned tools and components, and pre-configured safety protocols. When replacement is required, the system can execute the pre-planned actions immediately, minimizing actual replacement time while the complexity is amortized over the entire automated system.
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
The system enables safe and efficient battery pack replacement, preventing burning caused by short circuits and improving electric vehicle mileage and safety during driving.
Implementation Method 1
the second connection point of the first power supply protector's grounding conductor unloads and absorbs the large current entering along the first power line
Implementation Method 2
various parts of the grounding conduct currents into the earth through the conductive tyre
Implementation Method 3
The special chemical seal can rapidly absorb the heat produced during the process of surge protection
Data Source
AI summary
A battery pack replacement and explosion-proof system: Start to control the second battery pack robot system and the ferry robot to uninstall and install the first battery pack and the second battery pack; the second connection point of the first power supply protector's grounding conductor unloads and absorbs the large current entering along the first power line; the third connection point unloads and absorbs the large current along the second power line; the fifth connection point of the second power surge protector unloads and absorbs the large current along the third power line; the sixth connection point unloads and absorbs the large current along the fourth power line; the first connection point and the fourth connection point unloads and absorbs the large current along the first and the second control line and signal lines of BMS, various parts of the grounding conduct currents into the earth through the conductive tyre.