Patent Description:
A battery swapping executing mechanism for battery swapping for an electric vehicle is a guide rail-type automated battery swap trolley. Generally, an electric vehicle which requires a battery swap is lifted to a certain height above the ground, and the trolley moves along a track rail to an area below the vehicle. Firstly, the trolley is lifted to approach a battery, and the relative position of the trolley with respect to the battery is fixed; then the trolley removes the battery from the vehicle, descends with the battery, moves away from the vehicle along the track rail, and moves to a battery storage station to swap the battery for a fresh battery; and finally, the trolley moves to an area below the lifted vehicle again, repeats the foregoing actions, and installs the fresh battery onto the vehicle.

Currently, there are multiple types of automated battery swap systems in which the structures and principles of battery swap trolleys are significantly different, and battery swap processes are also different. <CIT> discloses a rail-guiding battery replacing robot comprising a body, a battery transporting part and a battery assembling-disassembling part. In the assembled state, the battery assembling-disassembling part is arranged in a mode such that the battery transporting part is not disturbed to increase the control space of the battery replacing robot. <CIT> discloses an alignment device and a positioning mechanism for swapping an electric installation, such as in a battery swapping station. <CIT> discloses a lifting carrying device comprising a walking mechanism, a lifting mechanism, a floating mechanism and an unlocking mechanism. The floating mechanism comprises a base and a positioning part, the base being fixedly connected to a lifting platform. Through the walking mechanism, the lifting carrying device is controlled to walk to a preset position, the lifting mechanism lifts carried equipment such as batteries of electric automobiles to a preset height, and the floating mechanism is generally used for bearing the carried equipment. <CIT> discloses a battery pack lift system which includes a frame having nutrunners mounted thereon according to a battery pack fastener pattern for a vehicle, a lift configured to raise and lower the frame with regard to the vehicle, a first air bearing positioned between the frame and the lift, the first air bearing configured to allow relative movement between the frame and the lift, and a second air bearing positioned on the frame, the second air bearing configured to allow relative movement between a battery pack and the frame.

One aspect of the application is to provide a battery swapping executing mechanism according to claim <NUM>.

Optionally, in the battery swapping executing mechanism, the lifting/lowering portion is provided with guide portions, the driving mechanism is provided with movable portions, the movable portions move in a second direction, the second direction is substantially perpendicular to the first direction, and one of the guide portion and the movable portion comprises a wedged surface, and the other of the two is mated with the wedged surface.

Optionally, in the battery swapping executing mechanism, the movable portion has a roller assembly, the guide portion has a wedged surface, and the roller assembly is mated with the wedged surface.

Optionally, in the battery swapping executing mechanism, the movable portion comprises a first roller and a second roller which are disposed coaxially, one of the first roller and the second roller is in contact with the base, and the other is in contact with the wedged surface.

Optionally, in the battery swapping executing mechanism, the lifting unit further comprises guide columns in the first direction, one end of each of the guide columns is arranged on the base, a lifting/lowering component of the lifting/lowering portion is provided with a through hole for the guide column to pass through, and the guide column is used for limiting a lifting/lowering trajectory, in the first direction, of the lifting/lowering component.

Optionally, in the battery swapping executing mechanism, a plurality of groups of guide portions and movable portions which are mated with each other are provided, the driving mechanism further comprises a first frame and a driving member, all the movable portions are disposed on the first frame, and motion output from the driving member drives one or more of the movable portions to move in the second direction, so as to drive the first frame to bring other movable portions into movement on the base in the second direction.

Optionally, in the battery swapping executing mechanism, the locking/unlocking unit has an opening for exposing the conveying unit, and when the locking/unlocking unit and the conveying unit are raised or lowered relative to each other, the top of the conveying unit is able to ascend from the opening to a level higher than the locking/unlocking unit or descend to a level lower than the locking/unlocking unit.

Optionally, in the battery swapping executing mechanism, the locking/unlocking unit comprises torque guns for locking and unlocking a battery, and battery pins and vehicle body pins which assist in battery locking and unlocking, wherein the battery pins are used for alignment with the battery before unlocking a battery, and the vehicle body pins are used for alignment with a vehicle body before locking a battery.

Optionally, in the battery swapping executing mechanism, the locking/unlocking unit further comprises a support block for lifting a battery.

Optionally, the battery swapping executing mechanism further comprises track rails arranged in the second direction, wherein docking and guiding units are disposed at one end of the track rails to guide a battery being exchanged; and the docking and guiding units are disposed at two sides, in a third direction, of the base, the third direction being substantially perpendicular to the second direction.

In the battery swapping executing mechanism according to the application, the height of the conveying unit for battery exchange is constant, and the lifting unit ascends or descends relative to the conveying unit such that the height of the locking/unlocking unit for locking or unlocking a battery can be higher or lower than the conveying unit, such that the switching between positions of the locking/unlocking unit and the conveying unit is achieved. The locking/unlocking unit is further provided with a space which is raised or lowered relative to the conveying unit. Because the conveying unit does not ascend or descend during the lifting/lowering, the battery swapping executing mechanism does not need to be lifted as a whole, such that the overall lifting height of the battery swapping executing mechanism is reduced. In addition, auxiliary positioning is carried out by raising or lowering the vehicle, such that the overall height of the battery swap station can also be reduced, and therefore the battery swapping executing mechanism in the application can be used in an underground parking garage.

As to a transmission unit, the solution of combining powered rollers and unpowered rollers is adopted, thereby omitting an additional electric motor for the conveying unit, and reducing the lifting weight and the costs.

The locking/unlocking unit is provided with the battery pins for alignment with the battery during battery detachment and the vehicle body pins for alignment with the vehicle body during battery installation. A separate electric pin can be used, which allows a small occupied space, a short pin stroke, and a high compatibility. The two types of pins are used for different battery swap steps, and the position of the locking/unlocking unit does not need to be memorized when the pins are aligned for the first time, thus simplifying the process and improving the positioning precision.

The docking and guiding units for guiding a battery to be exchanged are also mounted on the base of the battery swapping executing mechanism.

Other aspects and features of the application will become apparent from the following detailed description with reference to accompanying drawings. However, it should be understood that the accompanying drawings are designed for the purpose of explanation only and are not intended to limit the scope of the application, as they should refer to the appended claims. It should also be understood that the accompanying drawings are only intended to conceptually illustrate the structures and processes described herein and are not necessarily drawn to scale unless otherwise indicated.

The application will be more fully understood by referring to the following detailed description of specific embodiments in conjunction with the accompanying drawings, in which like reference numerals refer to like elements throughout the figures. In the figures:.

In order to help those skilled in the art to accurately understand the claimed subject matter of the application, the specific embodiments of the application will be described in detail below with reference to the accompanying drawings.

A battery swapping executing mechanism according to the application may be used as an automated battery swap rail trolley, also referred to as a rolling guide vehicle (RGV) and briefly referred to as a battery swap trolley below, and is used for battery swapping for an electric vehicle. The battery swap trolley is a rail vehicle, which moves back and forth between a battery compartment and a battery swap station along track rails, wherein an electric vehicle with a battery pack to be swapped enters the battery swap station. Herein, the battery can also be referred to as a battery pack, a battery module, etc., and is an integrated device for providing driving power to the electric vehicle. The battery swap trolley in a no-load state is moved to an area below a vehicle in the battery swap station, detaches a used battery pack from the vehicle, and transfers the used battery from the battery swap station to the battery compartment. The used battery is replaced with a fresh battery at the battery compartment. The battery swap trolley carrying the fresh battery is moved to the battery swap station again, and installs the fresh battery onto the vehicle. The above work flow is automated, is applicable to small battery swap places having a small height in space and can provide a modularly extended battery swap service.

<FIG> show schematic views of a structure of a battery swap trolley according to the application, and are exploded views. The exploded view in <FIG> includes a battery <NUM>, and the exploded views in <FIG> and <FIG> do not include a battery. As shown in <FIG>, the battery swap trolley comprises a base <NUM>, a locking/unlocking unit <NUM>, a conveying unit <NUM> and a lifting unit <NUM>, <NUM>. The lifting unit <NUM>, <NUM> comprises a driving mechanism <NUM> and a lifting/lowering portion <NUM> driven by the driving mechanism to ascend or descend. The conveying unit <NUM> is fixed on the base <NUM>, and the driving mechanism <NUM> is movable relative to the base <NUM>. The lifting/lowering portion <NUM> is located above the base <NUM> and is driven by the driving mechanism <NUM> to perform lifting/lowering motion. The lifting/lowering motion includes movement in a first direction x. The first direction x is a height direction.

Referring to <FIG> and <FIG>, the driving mechanism <NUM> is arranged on the base <NUM> and is movable in a second direction y relative to the base <NUM>. The second direction y is in a horizontal plane, and therefore is substantially perpendicular to the first direction x. The driving mechanism <NUM> comprises a driving member <NUM>, a first frame <NUM> and movable portions <NUM>. The driving member <NUM> is an electric motor having an output shaft connected to a lead screw <NUM>. The first frame <NUM> is an I-shaped frame, and nuts (not shown) matching the lead screw are integrated in the first frame <NUM>. The movable portions <NUM> are disposed on two end plates of the I-shaped frame. When the electric motor operates, rotary motion output by the electric motor is converted into movement of the first frame <NUM> in the second direction y by means of a lead screw-nut fit, such that the movable portions <NUM> are driven to move in the second direction y.

The movable portions <NUM> comprise four roller assemblies arranged on the first frame <NUM> respectively. Each roller assembly is formed by a first roller <NUM> and a second roller <NUM> which are coaxial. The first roller <NUM> has a larger roller diameter and is in contact with the base <NUM>, and the second roller <NUM> has a smaller roller diameter and is in contact with the lifting/lowering portion <NUM>.

The lifting/lowering portion is provided with guide portions <NUM>. There are four guide portions <NUM> corresponding to the movable portions <NUM>. Each guide portion <NUM> has a wedged surface <NUM>. Four wedged surfaces <NUM> are respectively arranged, in the form of wedged blocks, at two sides of a lifting plate <NUM> which functions as a lifting/lowering component. Each wedged surface <NUM> cooperates with the second roller <NUM> of each movable portion <NUM> such that, when the movable portion <NUM> moves, the guide portion <NUM> moves accordingly with the movable portion <NUM>. Definitely, the positions of the movable portion and the guide portion can be interchanged. Alternatively, it is also possible to provide a wedged surface on the movable portion such that the movable portion is mated with the guide portion with a wedge fit.

The lifting/lowering portion further comprises guide columns <NUM>. There are four guide columns <NUM>, with one end being inserted into a socket <NUM> on the base and the other end passing through a through hole <NUM> of the lifting plate <NUM>. The lifting plate <NUM> may ascend and descend in the first direction x relative to the guide columns <NUM>.

When the electric motor drives the first frame <NUM> to move, one or more movable portions are driven and actuate other movable portions to move. The first rollers <NUM> on the movable portions <NUM> move relative to the base <NUM>, and the wedged surfaces <NUM> move relative to the second rollers <NUM>. Because of the wedge effect of the wedged surfaces <NUM> and the movement of the lifting plate <NUM> relative to the guide columns <NUM>, the lifting plate <NUM> can be lifted or lowered. In some other implementations, the positions of the guide column and the socket can also be interchanged.

The locking/unlocking unit <NUM> is used for locking and unlocking a battery and is driven by the lifting/lowering portion <NUM> of the lifting unit to ascend or descend. The locking/unlocking unit <NUM> is connected to the lifting/lowering portion <NUM> by means of a floating mechanism which will be described below. Under the effect of the floating mechanism, the locking/unlocking unit <NUM> floats at least in a horizontal plane (perpendicular to the direction X). The locking/unlocking unit <NUM> may also ascend and descend in the first direction x along with the lifting/lowering portion <NUM>.

The conveying unit <NUM> is used for battery exchange and has a first support surface <NUM> for contact with the battery (denoted by arrows in <FIG> and <FIG>). The locking/unlocking unit <NUM> has a second support surface <NUM> for carrying the battery, and the conveying unit <NUM> and the locking/unlocking unit <NUM> can be raised or lowered relative to each other, to change a relative height position of the first support surface <NUM> and the second support surface <NUM>. As an example, the conveying unit <NUM> can be fixed to the base at a constant height, and the locking/unlocking unit can move up and down to change its height. The driving mechanism <NUM> drives the lifting/lowering portion <NUM> to ascend, and thus drives the locking/unlocking unit <NUM> to ascend, such that the second support surface <NUM> is higher than the first support surface <NUM>. The driving mechanism <NUM> drives the lifting/lowering portion <NUM> to descend, and thus drives the locking/unlocking unit <NUM> to descend, such that the second support surface <NUM> is lower than the first support surface <NUM>.

The conveying unit <NUM> comprises a roller transmission device. A roller surface of the roller transmission device forms the first support surface <NUM>. The roller transmission device is configured to convey a battery in the second direction y. The roller transmission device is formed by a plurality of roller carriers <NUM> arranged in the second direction y. As shown, a total of three roller carriers <NUM> are arranged in the second direction y to form one roller transmission device. The roller carriers <NUM>, at head and tail ends, of the three roller carriers <NUM> are provided with third powered rollers <NUM>; and the middle roller carrier is provided with fourth unpowered rollers <NUM>, i.e., driven rollers. In this way, the roller carriers <NUM> can be driven automatically, without the need of additionally disposing an electric motor and a transmission member for the roller transmission device.

There may be a plurality of roller transmission devices. In the embodiments shown, there are two roller transmission devices, which are respectively arranged at two sides, in a third direction z, of the base <NUM>. The third direction z is in a plane substantially perpendicular to the first direction x, and is substantially perpendicular to the second direction y. As a compact design, the two roller transmission devices can be spaced apart in the third direction z by the driving mechanism <NUM>. That is to say, the driving mechanism <NUM> and the lifting/lowering portion <NUM> are arranged in the middle of the base <NUM>, and the conveying unit is arranged at either side of the base <NUM>.

The lifting plate <NUM> is connected to the locking/unlocking unit <NUM> via the floating mechanism. The locking/unlocking unit <NUM> can float at least in a plane direction. The floating mechanism <NUM> facilitates the floating of the locking/unlocking unit <NUM> by utilizing chains. Four chains <NUM> and four columns <NUM> are respectively arranged at four corners of the lifting plate <NUM> (the number of the chains and the columns may be adjusted according to the actual layout). A first end (which is an upper end as shown) of the chain <NUM> is connected to the lifting plate <NUM>, and a second end (a lower end) is connected to the column <NUM>. The column <NUM> is L-shaped as shown, a first end (a lower end) of the column is connected to the chain <NUM> as described above, and a second end (an upper end) thereof is connected to the bottom of the locking/unlocking unit <NUM> by means of a flange <NUM>. When the lifting plate <NUM> ascends or descends, the lifting plate <NUM> drives the chains <NUM> and the columns <NUM> as well as the locking/unlocking unit <NUM> to move together in a same direction. When the locking/unlocking unit <NUM> needs to be aligned with a battery or a vehicle body, because of the chain <NUM>, the locking/unlocking unit <NUM> can float at least in the plane direction relative to the lifting plate <NUM> for adjusting the relative position.

The locking/unlocking unit <NUM> is used for installing a battery onto or detaching a battery from the vehicle. A main body structure of the locking/unlocking unit is a second frame <NUM>. The second frame <NUM> is provided with a space therein to accommodate the roller transmission device. As shown, the second frame <NUM> is divided into a plurality of smaller spaces <NUM>, and the area of a single small space <NUM> is substantially corresponding to the area of a single roller carrier <NUM> so as to expose the corresponding roller carrier <NUM>. Therefore, when the locking/unlocking unit ascends and descends relative to the roller transmission device, the roller carrier <NUM> can extend out of or retract back into the space <NUM>, such that one of the surfaces, i.e., the first support surface <NUM> and the second support surface <NUM>, of the two for contact with the battery can be higher or lower than the other one. Other areas where the roller carriers <NUM> do not need to be exposed can be covered with a cover plate <NUM> to provide a dustproof and aesthetic function, as shown in <FIG>. <FIG> and <FIG> are structural views of a battery swap trolley according to the application, and in this case, the battery swap trolley is in an initial state or has been lowered to return to the initial state. <FIG> is a schematic view including a battery <NUM>, and <FIG> does not include a battery. As shown, in this state, the roller transmission devices are in the spaces <NUM> of the locking/unlocking unit, and in the initial state, the conveying unit <NUM> carries the battery. Therefore, the first support surface of the conveying unit <NUM> is higher than the second support surface.

The locking/unlocking unit further comprises torque guns <NUM> for locking and unlocking the battery, vehicle body pins <NUM> for alignment with the vehicle body, battery pins <NUM> for alignment with the battery, and support blocks <NUM>, all these components being arranged at the top of the second frame <NUM>. The torque gun <NUM> has a relatively small size, and therefore a plurality of torque guns <NUM> can be arranged on the second frame <NUM>. A servo driving unit <NUM> for the torque guns is arranged on the base, and does not ascend or descend along with the lifting/lowering portion <NUM>. There are two types of pins on the second frame <NUM>, including the battery pins <NUM> and the vehicle body pins <NUM>, which are used for different scenarios. While the battery is detached from the vehicle, the battery pins <NUM> are aligned with the battery. The vehicle body pins <NUM> are arranged at top corners of the second frame <NUM>, and while a battery is installed onto the vehicle, the vehicle body pins <NUM> are aligned with the vehicle body. The battery pins <NUM> and/or the vehicle body pins <NUM> may be separate electric pins, allows a small occupied space, a short stroke, and a high compatibility. When the locking/unlocking unit carries the battery detached from the vehicle, the support blocks <NUM> function to carry the battery.

The battery swap trolley further comprises track rails <NUM> extending in the second direction y and a walking mechanism which drives the base <NUM> to walk along the track rail <NUM>. Referring to <FIG>, the walking mechanism comprises an electric motor (not shown), a gear (not shown), a rack <NUM> and a bearing. The rack <NUM> substantially parallel to the track rails <NUM>, i.e., extending in the second direction y, is arranged between the two track rails <NUM>. The track rails <NUM> are connected by guide rail supports <NUM>. The electric motor is a driving servo electric motor of the battery swap trolley, and is connected to the gear which is meshed with the rack <NUM>. The electric motor is started to drive the gear, and by means of a gear-rack transmission, wheels of the battery swap trolley moves, in the form of a bearing, in the track rails <NUM>. The bearing is mounted below the base, and the base movably walks on the track rails <NUM> by means of the bearing and moves between a battery compartment and a battery swap station in the second direction y along the track rails <NUM>.

Docking and guiding units <NUM> are disposed at one end of the track rail <NUM> to guide a battery being exchanged. The docking and guiding units <NUM> are disposed at two sides, in the third direction z, of the base <NUM>. Therefore, when the base <NUM> moves to this end along the track rails <NUM>, the roller transmission devices are located between the docking and guiding units <NUM>, and accordingly, the carried battery is also located between the docking and guiding units <NUM>. As shown, the docking and guiding units <NUM> are a pair of guide doors, with its height in the first direction x being greater than that of the roller carriers <NUM>, so as to limit the position of the battery in the third direction z. A clearance distance between the docking and guiding units <NUM> depends on a battery size. When the battery is conveyed from the battery swap trolley to the battery compartment or from the battery compartment to the battery swap trolley, the docking and guiding units <NUM> can limit the battery to being conveyed in the second direction y along an expected trajectory.

Referring to <FIG>, an exemplary operation manner of the battery swap process of the battery swap trolley is described below.

It should be noted that, the track rails and driving components thereof may not be included in the battery swapping executing mechanism, but are integrated into the battery swap station for a battery swap operation, or integrated into a manual battery swap trolley for a manual battery swap operation.

Claim 1:
A battery swapping actuating mechanism, comprising: a base (<NUM>), a locking/unlocking unit (<NUM>) for locking/unlocking a battery pack, a conveying unit (<NUM>) for conveying the battery pack, and a lifting unit, wherein
the lifting unit comprises a driving mechanism (<NUM>) and a lifting/lowering portion (<NUM>) that is able to be driven by the driving mechanism (<NUM>) to ascend or descend; and the locking/unlocking unit (<NUM>) is connected to the lifting/lowering portion (<NUM>) and is able to ascend or descend along with the lifting/lowering portion (<NUM>), such that the top of the locking/unlocking unit (<NUM>) is higher or lower than the conveying unit (<NUM>), and the conveying unit (<NUM>) is supported on the base (<NUM>), and
the locking/unlocking unit (<NUM>) is connected to the lifting/lowering portion (<NUM>) by means of a floating mechanism such that the locking/unlocking unit (<NUM>) floats at least in a horizontal plane,
characterized in that the floating mechanism comprises chains (<NUM>) and columns (<NUM>), each of the chains (<NUM>) has a first end connected to the lifting/lowering portion (<NUM>) in a first direction (x) and a second end connected to a first end of a respective one of the columns (<NUM>), the columns (<NUM>) are suspended to the lifting/lowering portion (<NUM>), and a second end of each of the columns (<NUM>) secures the locking/unlocking unit (<NUM>) in the first direction (x).