Floating Battery Module Mounting for Low-Impact Vehicle Swapping
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Solution Overview
Problem
Battery boxes in commercial vehicles are prone to damage from impacts and vibrations during operation and replacement due to the lack of a locking mechanism and high gravity center, and the existing battery replacement systems face challenges with precise location and safety risks due to uneven cargo and tire pressure.
Innovation Solution
A battery replacement device with a first floating structure and fixing device that includes a fixing substrate and a floating platform, featuring positioning portions and buffer members to alleviate vibrations and impacts, and a dual-floating hoisting battery replacement station with guided positioning and fast locking/unlocking mechanisms to ensure safety and stability during battery swapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery box is confined only by positioning pins at the bottom without a locking mechanism, then the installation process is simple, but the battery box is easily damaged by impacts during vehicle operation and replacement
Solution Approach 1:
The patent applies a floating structure that allows the battery box to dynamically adjust its position during impacts rather than being rigidly fixed. The floating platform can move vertically and horizontally within defined ranges, absorbing impact energy and preventing damage while maintaining secure positioning during normal operation
Solution Approach 2:
The patent incorporates buffer members between the battery box and the fixing substrate that provide beforehand cushioning against impacts. These buffers are pre-installed to absorb shock during vehicle operation and battery replacement, preventing damage before it occurs
2Power
If the battery system has high power consumption leading to high gravity center, then the power output is sufficient, but the battery structure is easily damaged during high-speed emergency braking
Solution Approach 1:
The patent uses the floating structure to counteract the harmful effects of the high gravity center during emergency braking. The floating platform can move to offset positions that balance the gravitational force, reducing the impact on the battery structure during high-speed emergency braking
3Strength
If the bottom of the battery pack is a rigid structure, then the structural strength is high, but the vibration amplitude during bumping is too large causing damage to the battery
Solution Approach 1:
The patent replaces the rigid bottom structure with a floating platform that has flexible connection characteristics. This flexible structure can deform and absorb vibration energy during bumping, significantly reducing vibration amplitude while maintaining sufficient structural strength through the floating mechanism
4Ease of operation
If there is no locking mechanism for the battery box, then the battery replacement process is simple, but the battery box is easily damaged by impacts
Solution Approach 1:
The floating structure provides dynamic protection during battery replacement without requiring complex locking mechanisms. The battery box can freely move on the floating platform during the replacement process, and the platform absorbs impacts automatically, maintaining both simplicity and reliability
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, enhances stability and safety by providing multi-level floating and positioning, and improves the accuracy and speed of battery swapping.
Implementation Method 1
The floating member includes an elastic member; 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
Implementation Method 2
a buffer limiting portion and a battery floating platform; a top surface of the battery floating platform is connected to the first battery module through the buffer limiting portion
Data Source
Figure 1
Figure 2~3
Figure 4(a)~4(b)
AI summary
The present application provides a battery replacement device for vehicles, a dual-floating hoisting battery replacement station, and a battery replacement system. The battery replacement device for vehicles comprises a battery module, a first floating structure, and a fixing device, the fixing device is used for fixing the battery module on a longitudinal beam of a vehicle, the fixing device comprises a fixing substrate, the first floating structure is disposed between the battery module and the fixing substrate, and the first floating structure is used for reducing the vibration amplitude of the battery module. According to the battery replacement device for vehicles provided in the present application, a first floating structure is provided between the battery module and the fixing substrate and the floating structure is used for floating connection between the battery module and the vehicle, the vibration amplitude of the battery module during vehicle driving can be effectively reduced and impact to the battery module during battery replacement can be reduced.