Battery exchange system and method
20210261017 · 2021-08-26
Assignee
Inventors
Cpc classification
B60L53/80
PERFORMING OPERATIONS; TRANSPORTING
B60S5/06
PERFORMING OPERATIONS; TRANSPORTING
H01M50/264
ELECTRICITY
B60K2001/0455
PERFORMING OPERATIONS; TRANSPORTING
H01M50/249
ELECTRICITY
Y02T10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M2220/20
ELECTRICITY
B60K1/04
PERFORMING OPERATIONS; TRANSPORTING
H01M50/244
ELECTRICITY
B60L50/64
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/7072
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B60L53/80
PERFORMING OPERATIONS; TRANSPORTING
B60K1/04
PERFORMING OPERATIONS; TRANSPORTING
B60L50/60
PERFORMING OPERATIONS; TRANSPORTING
B60L50/64
PERFORMING OPERATIONS; TRANSPORTING
B60S5/06
PERFORMING OPERATIONS; TRANSPORTING
H01M50/244
ELECTRICITY
H01M50/249
ELECTRICITY
Abstract
Battery exchange system for an electric vehicle, comprising: a battery unit; a battery receiving unit adapted for being fixed at or near a bottom surface of an electric vehicle and comprising a housing with an opening at a bottom side of housing for at least partially receiving the battery unit in the housing through the opening, wherein the battery receiving unit has a central axis which extends through the opening; wherein the battery receiving unit is adapted for allowing movement of the battery unit along its central axis between an unmounted position below the battery receiving unit and a mounted position at least partially within the battery receiving unit, wherein the battery unit comprises first engagement elements and the battery receiving unit comprises second engagement elements, each of the first and second engagement elements being adapted for engaging each other while moving relative to each other along an associated sloping path in order to lift the battery unit from the unmounted position to the mounted position or lower the battery unit from the mounted position to the unmounted position, wherein said associated sloping path slopes with respect to a plane normal to the central axis.
Claims
1. A battery exchange system for an electric vehicle, comprising: a battery unit comprising a bottom surface, a top surface and a circumferential side surface extending therebetween; a battery receiving unit adapted for being fixed at or near an underside of the electric vehicle and comprising a housing with an opening at a bottom side of the housing for at least partially receiving the battery unit in the housing through the opening, wherein the battery receiving unit has a central axis which extends through the opening; wherein the battery receiving unit is adapted for allowing movement of the battery unit along the central axis between an unmounted position below the battery receiving unit and a mounted position at least partially within the battery receiving unit, wherein the battery unit comprises first engagement elements and the battery receiving unit comprises second engagement elements, each of the first and second engagement elements being adapted for engaging each other while moving relative to each other along an associated sloping path in order to lift the battery unit from the unmounted position to the mounted position or lower the battery unit from the mounted position to the unmounted position, wherein said associated sloping path slopes with respect to a plane normal to the central axis.
2. The system according to claim 1, wherein the second engagement elements are adapted for moving relative to the housing in a common plane that is substantially normal to the central axis.
3. The system according to claim 1, wherein each of said sloping paths associated with one of said first engagement elements and one of said second engagement elements is spaced apart from the other sloping paths which are associated with another of the first engagement elements and another of the second engagement elements, each of said sloping paths comprising a starting point and an end point, wherein the starting points of the sloping paths lie in a first common plane, and the end points of the sloping paths lie in a second common plane.
4. The system according to claim 3, wherein the slope of each path extending between the first common plane and the second common plane has a positive gradient of less than 25 degrees from the first plane along the entire length of the path between the first plane and the second plane.
5. The system according to claim 3, wherein the first and second engagement elements form pairs of first and second engagement elements for engaging each other, wherein in each pair one of the first and second engagement elements comprises a portion adapted for engaging the other element of said pair during movement of the battery unit between the mounted and unmounted position, wherein said portion is ramped with respect to said first and second planes.
6. The system according to claim 1, wherein each of said sloping paths is formed as a segment of a substantially helical path.
7. The system according to claim 1, wherein the gradient of each of said sloping paths varies and decreases monotonically along the path from the starting point towards the end point.
8. (canceled)
9. The system according to claim 1, wherein the first and second engagement elements are adapted for engaging each other while moving relative to each other along said sloping path to lift or lower the battery unit between the unmounted and mounted position such that the battery unit is lifted or lowered along the central axis in a substantially translational motion during which the battery unit rotates, in a plane normal to the central axis, no more than 10 degrees around the central axis.
10. The system according to claim 1, wherein the battery receiving unit comprises at least three second engagement elements, preferably wherein the second engagement elements are circumferentially spaced apart from each other when viewed in projection onto the plane normal to the central axis.
11. The system according to claim 1, wherein the battery receiving unit further comprises one or more actuators for moving the first and second engaging elements relative to each other along their associated paths in order to lift the battery unit from the unmounted position to the mounted position or lower the battery unit from the mounted position to the unmounted position, preferably while driving movement of the second engagement elements relative to the housing in a common plane that is substantially normal to the central axis.
12. (canceled)
13. The system according to claim 1, wherein when viewed in projection onto said plane normal to the central axis, each of said paths has a length of less than one sixth of the circumferential length of the circumferential side surface.
14. The system according to claim 1, wherein the opening has a non-circular shape which substantially matches the shape of the circumferential side surface of the battery unit.
15. The system according to claim 1, wherein the first and second engagement elements form pairs of first and second engagement elements for engaging each other, wherein in each pair one of the first and second engagement elements comprises one or more rollers for rolling engagement with the other element of said pair during movement of the battery unit between the mounted and unmounted position.
16. The system according to claim 1, wherein the battery receiving unit comprises a support ring that is rotatable relative to the housing around the central axis of the battery receiving unit, wherein the second engagement elements are mounted on the support ring.
17. (canceled)
18. The system according to claim 16, wherein the battery receiving unit further comprises a mechanical locking mechanism for locking the battery unit in position when the battery unit is in the mounted position.
19. (canceled)
20. The system according to claim 1, wherein the circumferential side surface of the battery unit, when viewed in projection onto a plane normal to a central axis of the battery unit which extends through the top and bottom surface, has a non-circular outer contour, preferably a polygonal or ellipse-shaped contour.
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. (canceled)
26. (canceled)
27. An electric vehicle comprising a battery receiving unit for at least partially receiving therein a battery unit that is provided with first engagement elements, wherein the battery receiving unit is fixed at or near an underside of the electric vehicle and comprises a housing with an opening at a bottom side of the housing for at least partially receiving the battery unit in the housing through the opening, wherein the battery receiving unit has a central axis which extends through the opening; wherein the battery receiving unit comprises second engagement elements, each of said second engagement elements adapted for engaging a first engagement element of said battery unit while moving both relative to the housing in a common plane that is substantially normal to the central axis and relative to said first engagement element along an associated sloping path in order to lift the battery unit from an unmounted position to a mounted position or lower the battery unit from the mounted position to the unmounted position, wherein said associated sloping path slopes with respect to a plane normal to the central axis.
28. The electric vehicle according to claim 27, wherein the battery receiving unit further comprises one or more actuators for driving movement of the second engaging elements relative to the corresponding first engagement elements along their associated paths, and relative to the housing.
29. A battery exchange method for an electric vehicle comprising a battery receiving unit fixed at a bottom side of the vehicle and comprising a housing with an opening at a bottom side of the housing for at least partially receiving the battery unit in the housing through the opening, wherein the battery receiving unit has a central axis which extends through the opening and is further provided with second engagement elements arranged within the housing, the method comprising: i) placing a battery unit below the opening of the housing, such that, wherein viewed in projection onto a plane normal to the central axis, the battery unit is completely overlapped by the opening, the battery unit comprising first engaging elements for engagement with said second engagement elements, ii) using a lifting device external to the electric vehicle, lifting the battery unit towards the opening to an unmounted position; and iii) moving each of the second engagement elements into engagement with a corresponding one of said first engagement elements, and subsequently driving further movement the each of the first and second engagement elements relative to each other along an associated sloping path in order to lift the battery unit from the unmounted position to the mounted position, wherein each of said associated sloping paths slopes with respect to a plane normal to the central axis.
30. (canceled)
31. The method according to claim 29, wherein the battery receiving unit comprises a support ring that is rotatable relative to the housing around the central axis of the battery receiving unit, wherein the second engagement elements are mounted on the support ring, and step iii) comprises driving rotation of support around the central axis for bringing the first and second engagement elements into engagement with each other and driving said further movement of the first and second engagement elements along the associated sloping paths.
Description
SHORT DESCRIPTION OF DRAWINGS
[0045] The present invention will be discussed in more detail below, with reference to the attached drawings, in which
[0046]
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[0048]
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[0050]
DESCRIPTION OF EMBODIMENTS
[0051]
[0052]
[0053] The first engagement elements 25 are formed as separate ramped portions that attached, e.g. by welding, to the inner surface of the circumferential side surface 23 near edge 22 of the battery unit which forms an upper surface of the battery unit.
[0054] The battery unit 20 of the system 1 comprises a series of batteries in a container 28, here shown schematically, the container surrounding the batteries in a substantially water tight manner. An electrical connector 24 is provided at a top side of the container 28 and is arranged to coincide substantially with the central axis when the battery unit is in the mounted position. Electrical power can be supplied from the batteries within the container 28, via the electrical connector 24, to the electric vehicle. The full height of the battery exchange system 1, including the battery receiving unit, is no more than 20 cm when the battery unit 20 is held in the mounted position in the battery receiving unit 10. The battery unit typically has a diameter between 80 cm and 130 cm. As a result the system can easily be integrated in existing vehicle designs or built into existing vehicles without negatively impacting the loading space capacity or ride height too much. For trucks and other heavy vehicles these dimensions may be scaled up depending on their power requirements and/or size constraints.
[0055]
[0056] The circumferential sidewall 17 extends from the bottom plate 13 towards the bottom plate 16b of the top section 12, and the circumferential outer side plate 15 extends from the bottom plate 16b to the top plate 16a such that, when the bottom section 18 of the battery receiving unit is attached to the top section 12, the battery receiving unit 10 forms a battery unit receiving space that is substantially closed except at the battery receiving opening 11.
[0057]
[0058] The second engagement element 35 is shown engaging the first engagement element 25 on a downwardly directed surface of portion 29c of the track which portion extends substantially normal to the central axis C. The first and second engagement elements can move relative to each other along the path defined by the track, for moving the battery unit guided between an unmounted and a mounted position. Due to the shape of the tracks, the engagement elements 25, 35 can engage each other when the ring is rotated while he battery unit is arranged partially within the opening. Thus, even if battery's central axis which extends normal to its bottom surface is not completely aligned with the central axis C of the battery receiving unit 10, rotation of the ring may drive relative movement between the first and second engagement elements, where upon during further rotation of the ring the two central axis will become substantially aligned with each other.
[0059] Sloping portion 29a extends at an angle of about 11 degrees to plane P1 in the direction from the starting point towards the end point and transitions into sloping portion 29b which extends at an angle of about 5 degrees to said plane P1 in the direction towards the end point 27, as can be seen more clearly in
[0060] The portion 29a which comprises the start 26 of the sloping path has a greater slope to the plane P1 and a shorter length than the subsequent portion 29b. Track portion 29c which runs from the end point 27 of the sloping path is substantially parallel to the plane P1.
[0061] The total length of each track of the first engagement elements 25 shown in
[0062] In the configuration of
[0063]
[0064] The pinion gear actuator 39a can be driven to drive rotation of the rotary ring 31 in a first direction, to allow the second engagement elements 35 to meet up with the first engagement elements 25 at their respective starting points 26, the first and second engagement elements in this manner forming pairs, each first and second engagement element of a pair moving with respect to each along a substantially helical path dictated by the shape of the track of the first engagement elements 25. As the first and second engagement elements 25, 35 follow this path with respect to each other in a first direction, the battery unit 20 is lifted from the unmounted position to the mounted position. The end points 27 of the tracks of the first engagement elements 25 coincide with the end point of the path and the mounted position of the battery unit 20 inside the battery receiving unit 10. When the pinion gear actuator 39a is driven to drive rotation of the rotary lock ring 31 in a second direction opposite from the first direction, the first and second engagement element pairs move in opposite direction with respect to each other, resulting in the path being followed in the opposite direction and the battery unit being lowered from the mounted position to the unmounted position.
[0065] Though not shown in the figures, the battery receiving unit may comprise sensors on one or more internal surfaces of the battery receiving unit facing the opening 11. These sensors can be set up to determine the location of a plane in which the engagement points, or starting points 26, of the first engagement elements 25 with respect to a plane in which the engagement points of the second engagement elements 35 are located, such that the actuators are only activated if these planes are aligned. The sensors could be powered independent from the battery unit 20 by making use of a small internal back-up battery in the electric vehicle, which recharges itself upon installation of the battery unit, making use of the energy stored therein. This same back-up battery may be used to power the one or more actuators of battery lifting system 30.
[0066] Though in the embodiments illustrated in the preceding figures the first and second engagement elements are shaped and arranged to move along substantially helical paths relative to each other when lifting the battery unit from the unmounted position to the mounted position or lowering the battery unit from the mounted position to the unmounted position, and both the opening and the battery unit have a substantially circle-shaped contour, it is noted that neither is required for the invention to work.
[0067]
[0068]
[0069] In
[0070]
[0071]
[0072]
[0073]
[0074] In
[0075] Once the engagement surfaces of the first and second engagement elements 25, 35 are substantially located in a single plane, a rotating motion around the central axis C of ring 31 causes said first and second engagement elements to move with respect to each other along associated helical paths, thus lifts the battery unit 20 into the mounted, final position inside the battery receiving unit 10. In the mounted position shown in
[0076] When a simple battery lifting system is implemented, wherein the first engagement elements 25 are fixedly and stationary mounted onto the battery unit 20 and the second engagement elements 35 are fixedly and stationary mounted onto the battery receiving unit 10, the external lifting system 40 may be used to drive rotation around the central axis C between the first and second engagement elements. It is however preferred that the battery receiving unit comprises a battery unit lifting system as described for
[0077] In order to move the battery unit from the mounted position to the unmounted position, the motions shown in
[0078] The present invention has been described above with reference to a number of exemplary embodiments as shown in the drawings. Modifications and alternative implementations of some parts or elements are possible, and are included in the scope of protection as defined in the appended claims.