Swappable EV Battery Mounting Assembly for Secure Fast Exchange
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Solution Overview
Problem
Existing electric vehicles, particularly electric tractors, face challenges with battery pack swapping due to weight and accessibility issues, leading to reduced productivity and higher maintenance costs.
Innovation Solution
A system and method for swapping battery packs in electric vehicles, featuring a mounting assembly with linear and rotational movement mechanisms, allowing for easy access and orientation of the battery pack, and an integrated battery management system for communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the battery pack is securely connected within the vehicle forming an integral part, then the battery pack stability and security are improved, but the ease of removal and swapping is worsened
Solution Approach 1:
The battery pack system is segmented into a removable battery pack unit and a vehicle mounting structure. The battery pack is designed as a separate modular unit that can be independently removed and replaced, resolving the contradiction between secure connection and ease of removal through structured segmentation.
Solution Approach 2:
The mounting assembly incorporates dynamic elements including linear movement mechanisms and rotational movement mechanisms that enable the battery pack to be easily inserted and removed. These dynamic components allow the battery pack to transition between secured and removable states, maintaining both security and ease of operation.
2Power
If the battery pack capacity is increased to meet higher power requirements, then the power supply capability is improved, but the charging time and vehicle idle time are worsened
Solution Approach 1:
Instead of charging the battery pack in place (which causes vehicle idle time), the system enables preliminary charging of replacement battery packs externally while the vehicle is in operation. This allows continuous operation by swapping in pre-charged packs, eliminating the time loss associated with on-vehicle charging.
Solution Approach 2:
The swappable battery pack system enables continuous useful action by allowing the vehicle to operate continuously with multiple battery packs. While one battery pack is in use, another can be charged externally, ensuring the vehicle never stops operating and maintaining continuous productivity.
3Ease of operation
If the battery pack is made accessible for swapping, then the ease of swapping is improved, but the structural integrity and security of the vehicle is worsened
Solution Approach 1:
The vehicle structure is segmented to include a dedicated battery mounting assembly that is structurally integrated into the vehicle chassis. This segmentation allows the battery pack to be easily accessible for swapping while the mounting assembly maintains the structural integrity of the overall vehicle.
Solution Approach 2:
The mounting assembly acts as an intermediary between the battery pack and the vehicle chassis. It provides a secure structural connection point that maintains vehicle integrity while enabling easy battery pack removal and installation through its designed movement mechanisms.
4Ease of operation
If the mounting assembly includes linear and rotational movement mechanisms, then the ease of battery pack orientation and swapping is improved, but the device complexity is worsened
Solution Approach 1:
The linear movement mechanism and rotational movement mechanism are merged into a single integrated mounting assembly. This combination allows both linear insertion/removal and rotational orientation adjustments to be achieved through one unified structure, reducing overall system complexity while maintaining ease of operation.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The disclosure herein generally relates to swappable battery pack and more particularly, to a system and method for swapping a battery pack in an electric vehicle. The system (100) includes a mounting assembly (104) mounted on a chassis (10) of the vehicle, and at least one battery pack (102) mounted on the mounting assembly (104). The mounting assembly facilitates linear and rotational movement of the battery pack w.r.t the chassis to allow egress and ingress of the battery pack (102) from a battery mounting space defined in the vehicle. At least two connectors (106C) provided on a mounting platform (106) facilitate connection of the battery pack with the vehicle. The system facilitates ease in accessing the battery pack, allows the battery pack to be removed and placed at different orientations, easy to assemble and operate.