Floating Battery Mount and Locking for Vibration-Safe Swapping
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Solution Overview
Problem
Battery boxes in commercial vehicles are prone to damage due to high vibration amplitudes during driving and impact during battery replacement, and the lack of a locking mechanism leads to safety risks during battery swapping.
Innovation Solution
A battery replacement device with a first floating structure and fixing device that includes a fixing substrate and a floating platform to alleviate vibration and impact, combined with a dual-floating hoisting battery replacement station for precise grabbing and locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the battery box is confined only by positioning pins along three directions at the bottom without a locking mechanism, then the device complexity is reduced, but the reliability and safety of the battery system deteriorate under impact conditions
Solution Approach 1:
The patent applies the dynamics principle by introducing a locking mechanism that can transition between locked and unlocked states. The locking mechanism includes a locking block that can engage with a locking groove on the battery box, transforming the static positioning pin system into a dynamic system capable of adapting to different operational states (normal operation vs. impact conditions), thereby improving reliability without permanently increasing complexity.
Solution Approach 2:
The patent segments the fixing mechanism into distinct functional components: positioning pins for initial location, a locking mechanism for secure fixation, and a buffer structure for impact absorption. This segmentation allows each component to perform its specific function optimally, with the locking mechanism providing enhanced reliability during impact conditions while maintaining overall system manageability.
2Strength
If the bottom structure uses a rigid structure for the battery pack, then the manufacturing precision and structural strength are improved, but the battery is more susceptible to damage during bumping due to large vibration amplitude
Solution Approach 1:
The patent applies beforehand cushioning by introducing a buffer structure between the battery pack and the bottom structure. This buffer structure includes elastic elements that can deform to absorb impact energy before it reaches the battery pack, providing protective cushioning in advance of potential bumping events and reducing vibration transmission to the battery.
Solution Approach 2:
The patent employs flexible elements in the buffer structure that can deform elastically under vibration and impact loads. These flexible components act as shock absorbers, allowing the system to maintain structural strength while accommodating vibration movements, thereby protecting the battery from damage during bumping conditions.
3Ease of operation
If the grabbing device in the battery replacement station is used without accounting for uneven cargo quality and vehicle deformation, then the ease of operation is maintained, but the positioning precision and safety during battery replacement deteriorate
Solution Approach 1:
The patent applies feedback by incorporating sensors and detection mechanisms in the battery replacement station that can detect the actual position and state of the battery pack during replacement. This feedback information is used to adjust the grabbing device's positioning and operation in real-time, compensating for variations caused by uneven cargo quality and vehicle deformation, thereby maintaining both ease of operation and positioning precision.
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 solution effectively reduces vibration amplitude and impact on battery modules during vehicle operation and replacement, enhancing safety and stability by providing precise positioning and locking mechanisms.
Implementation Method 1
The first floating structure is provided between the first battery module and the fixing substrate, and can alleviate a vibration amplitude of the first battery module
Data Source
AI summary
A battery replacement device for vehicles includes a battery module, a first floating structure and a fixing device, the fixing device is used to fix the battery module on the longitudinal beam of the vehicle, the fixing device includes a fixing substrate, the first floating structure is provided between the battery module and the fixing substrate, and the first floating structure is used to alleviate a vibration amplitude of the battery module.