Modular Battery Swap Station with Segmented Storage Modules
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Solution Overview
Problem
Existing battery swap stations have a large footprint, low modularization degree, and poor extendibility, making them inflexible for maintenance, transportation, and adaptation to different battery types, particularly those with charging plugs on top, which complicates automatic parking and charging.
Innovation Solution
A modularized extendable battery swap station device with a charging rack and battery transfer device, featuring multiple independent storage modules, a layered structure, and a lift module, allowing for vertical and transverse movement of batteries, enabling flexible scaling and deployment in various environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral steel structure is used for the battery swap station, then structural strength is improved, but modularization degree deteriorates and extendibility deteriorates
Solution Approach 1:
The battery swap station is divided into multiple independent battery storage modules that can be separately assembled and disassembled. Each module contains its own support structure, locking mechanism, and charging components, enabling modular deployment and flexible expansion while maintaining structural integrity through standardized connection interfaces.
Solution Approach 2:
The support structure incorporates movable components including a battery transfer device with vertical and transverse movement capabilities, and a lift module that enables dynamic adjustment of battery positions. This dynamic design allows the system to adapt to different battery configurations and swap operations while maintaining structural strength.
2Manufacturing precision
If the battery swap station is designed with fixed scale, then manufacturing precision is improved, but adaptability to different sites and battery types deteriorates
Solution Approach 1:
The station uses standardized modular battery storage modules that can be configured in different numbers and arrangements based on site requirements. Each module maintains precise manufacturing specifications while the overall system scale can be flexibly adjusted by adding or removing modules to match different battery types and location constraints.
Solution Approach 2:
The battery storage modules and support structure are designed with universal interfaces and standardized dimensions that accommodate different battery types and configurations. The lift module and battery transfer device can handle various battery positions (side-face or top plugs), making the system universally applicable to different sites and battery specifications.
3Duration of action of stationary object
If AC slow-charging mode is used, then battery cycle life is improved, but charging time increases and productivity deteriorates
Solution Approach 1:
Batteries are pre-charged to full capacity in the battery storage modules before being deployed to vehicles. This preliminary charging action occurs in advance, allowing the vehicle-mounted batteries to be quickly swapped out when needed, thus achieving rapid power replenishment without subjecting batteries to prolonged high-current charging that would reduce cycle life.
Solution Approach 2:
The battery swap station acts as an intermediary charging infrastructure between the power grid and vehicles. It provides a buffer by maintaining inventory of pre-charged batteries, decoupling the charging process from the vehicle usage process and enabling rapid battery replacement without compromising battery longevity through gentle charging in the storage modules.
4Productivity
If DC fast-charging mode is used, then charging time is reduced and productivity is improved, but battery cycle life deteriorates and fully-charged state cannot be reached
Solution Approach 1:
Batteries undergo complete charging in the battery storage modules before being transferred to vehicles, achieving a fully-charged state in advance under controlled conditions. This preliminary action ensures maximum energy capacity without the negative effects of fast-charging, and enables rapid battery swap at the vehicle level without compromising battery health.
Solution Approach 2:
The battery swap station serves as an intermediary that separates the charging function from the vehicle operation function. It maintains a fleet of pre-charged batteries and performs rapid exchanges with vehicles, eliminating the need for fast-charging at the vehicle level while ensuring batteries reach full charge capacity through controlled charging in the storage modules.
Data Source
AI summary
A modularized extendable battery changing station device and a charging rack are disclosed, which belong to the technical field of electric vehicle battery charging and swapping. The present technical solutions aim to the solve problems of occupying a large area, a low modularity degree and poor extendibility of the existing battery changing station. For this purpose, the battery changing station device provided in the present technical solutions comprises a charging rack and a battery transfer device; the charging rack comprises at least a battery storage module, the battery storage module being able to realize the storage and charging of a battery, and the battery transfer device being able to pass through the battery storage module. The extendable battery changing station device provided in the technical solutions is able to integrate the functions of power battery transfer, storage and charging.