Modular Battery Conveyor System for Rapid EV Swapping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and weight of batteries in electric vehicles (EVs) make them unaffordable for the mass market, as current battery technology requires large, heavy, and expensive batteries to achieve a comparable driving range to gasoline-powered vehicles, and existing battery swapping systems are complex and costly to implement.
Innovation Solution
Standardized, lightweight (less than 80 pounds) batteries are designed to be easily replaceable, with a conveyor system allowing for quick exchange at home or at gas stations, reducing the initial vehicle cost and enabling widespread adoption by using government loans to support battery manufacturing and infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If large-capacity batteries are used to achieve comparable driving range to gasoline-powered vehicles, then driving range is improved, but vehicle cost and battery weight increase significantly
Solution Approach 1:
The patent divides the battery system into multiple separate, standardized battery packs (e.g., six 12-volt packs) that can be individually handled and exchanged. Each pack weighs less than 80 pounds, making them manageable for manual exchange while collectively providing the necessary driving range when combined in series to produce higher voltages (e.g., 72 volts).
Solution Approach 2:
The system enables dynamic reconfiguration of battery capacity by allowing users to exchange individual battery packs based on driving needs. The conveyor system facilitates rapid exchange of discharged packs with charged ones, dynamically adjusting the effective battery capacity without requiring the vehicle to be stationary at a charging station for extended periods.
2Duration of action of moving object
If large-capacity batteries are used to achieve comparable driving range to gasoline-powered vehicles, then driving range is improved, but vehicle cost increases significantly
Solution Approach 1:
The battery system is segmented into multiple standardized, modular packs that can be manufactured independently using conventional battery technology. This segmentation allows for economies of scale in manufacturing individual packs and reduces the upfront cost burden on consumers, as they only need to purchase or lease the vehicle with a basic set of packs rather than a complete large-capacity battery system.
Solution Approach 2:
The standardized battery packs are designed to be universally compatible across different vehicle models and applications. A single pack design can be used in multiple vehicle types, and the same packs can serve different functions (e.g., propulsion, auxiliary power) depending on how they are configured and connected in the vehicle's electrical system.
3Ease of operation
If conventional battery swapping systems are implemented, then battery exchange capability is provided, but system complexity and implementation cost increase
Solution Approach 1:
The system is designed to enable self-service battery exchange by vehicle owners without requiring specialized equipment or trained personnel. The standardized packs are sized and shaped for manual handling, and the conveyor system can be operated by the vehicle owner themselves to exchange packs at home or at simple exchange locations such as gas stations.
Solution Approach 2:
A conveyor system acts as an intermediary mechanism that simplifies the battery exchange process. The conveyor automatically guides and positions the battery packs during exchange, reducing the manual effort and complexity required compared to direct manual installation. The conveyor serves as a mediating device that bridges the gap between the user and the battery packs.
Data Source
AI summary
An electrical vehicle including a vehicle body, a passenger compartment, a chassis supporting the passenger compartment, a plurality of wheels and at least one electrical motor for driving the wheels. A battery compartment of the vehicle is configured to removably mount therein a plurality of more than two rechargeable batteries which are movable into position in the battery compartment by a battery conveyor system which has a battery access opening through which batteries are installed or removed, one by one, to and from the battery compartment. In the battery compartment, a connection mechanism effects the needed mechanical and electrical connections. An overall control system controls the conveyor system and the connection mechanism to enable rapid replacement of the removable batteries, whereby an electrical vehicle can be instantly driven, even after its batteries have been discharged by a replacement of the discharged batteries and the installation of freshly charged batteries.