Swappable Battery Pack Architecture for Electric Refuse Vehicles
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Solution Overview
Problem
The slow charging process of electric refuse vehicles due to current battery technology limits their availability for use, as it is a time-consuming process that interferes with their operational uptime.
Innovation Solution
A removable and modular energy storage and generation system for refuse vehicles that allows for quick swapping of depleted energy systems with fully charged ones, reducing downtime and enabling faster charging outside of the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric refuse vehicle uses a fixed battery system, then the vehicle structure is simple and reliable, but the charging time is long and operational availability is reduced
Solution Approach 1:
The battery system is segmented into multiple removable battery packs that can be independently exchanged. Each battery pack is a self-contained module with standardized interfaces, allowing the vehicle to quickly swap depleted packs with charged ones without requiring lengthy charging cycles, thus maintaining high vehicle availability while reducing charging time loss.
Solution Approach 2:
The system enables parameter changes by allowing substitution of battery packs with different charge states. Instead of charging a single fixed battery system in place, the vehicle can change the operational parameter (charge level) by exchanging packs, transforming the charging process from a time-consuming in-situ operation to a rapid swap operation that minimizes downtime.
2Loss of time
If the refuse vehicle uses a removable energy system, then the charging time is reduced through quick swapping, but the device complexity increases
Solution Approach 1:
The removable energy system employs universal standardized interfaces and mounting mechanisms that serve multiple functions: mechanical attachment, electrical connection, and structural support. This multi-functionality reduces the number of separate components needed, managing device complexity while enabling rapid swapping to reduce charging time.
Solution Approach 2:
The battery system is extracted from the vehicle's permanent structure into removable packs that can be independently handled. This extraction simplifies the swapping operation by isolating the complex battery components into discrete, manageable units with standardized interfaces, reducing the overall system complexity while enabling rapid replacement to minimize charging time.
3Productivity
If multiple energy systems are maintained for swapping, then the operational uptime is improved, but the quantity of energy systems required increases
Solution Approach 1:
Battery packs are charged in advance outside the vehicle using external charging infrastructure, rather than charging them while in the vehicle. This preliminary action allows multiple packs to be prepared simultaneously in parallel, reducing the number of packs needed compared to sequential charging, while maintaining high operational uptime through rapid swapping.
Solution Approach 2:
The system merges the vehicle's energy storage needs with external charging infrastructure. By combining the removable battery packs with off-vehicle charging capabilities, the system achieves high operational uptime without requiring a large fleet of identical vehicle-mounted battery systems, as packs can be charged externally and swapped in quickly.
Data Source
AI summary
A refuse vehicle includes a chassis, a refuse container coupled to the chassis, a tractive assembly coupled to the chassis and configured to propel the refuse vehicle, and an electric energy system configured to provide electrical energy to drive the tractive assembly. In a first configuration, a first energy system is removably coupled to the chassis and configured to provide the electrical energy to the electric energy system and in a second configuration, the first energy system is removed from the chassis and replaced with a second energy system, the second energy system removably coupled to the chassis and configured to provide the electrical energy to the electric energy system.