Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated EV battery diagnostic and servicing system for precise diagnostic, servicing, and maintenance of electric vehicle batteries in view of ensuring accuracy, safety, and compatibility across diverse battery types and vehicle configurations.

BACKGROUND OF THE INVENTION

[0002] The rapid growth of electric vehicles (EVs) has led to an increasing demand for efficient and automated solutions for the maintenance and servicing of EV batteries, which are critical to the performance, longevity, and safety of these vehicles. Traditional battery maintenance methods often require manual intervention, which are time-consuming and prone to human error. Furthermore, the complexity of modern EV batteries, particularly the wide variety of battery types and configurations, has added challenges for service stations and maintenance facilities in providing consistent and accurate diagnostics.

[0003] One significant challenge in the servicing of EV batteries is the diversity of battery types used across different electric vehicle models. Each battery has unique specifications for charging, discharge, maintenance, and replacement, which complicates the process of diagnosing faults and carrying out necessary repairs. Additionally, the physical handling of large and heavy batteries poses safety risks to technicians and damage sensitive components.

[0004] Another critical issue in the maintenance of EV batteries is the need for effective cleaning and conditioning of battery terminals and cells, which suffer from corrosion, dirt accumulation, and electrolyte imbalances over time. Corroded terminals, in particular, lead to poor electrical contact, reducing the overall efficiency of the battery and increasing the risk of electrical failures. Conventional cleaning techniques are often manual and involve hazardous materials or require significant technician time. As electric vehicle usage continues to rise, the importance of developing means for routine cleaning, electrolyte management, and terminal maintenance becomes increasingly apparent to ensure the optimal performance and lifespan of EV batteries.

[0005] US20140285936A1 discloses about an invention battery management system for a vehicle having an electrically powered motor that is powered by a plurality of battery cells includes an electrical system for providing voltage and current from the battery cells to an electrical motor. A control is operable to at least one of (a) cause fuses of the electrical system to be the weakest link in the electrical system only during a failure event, (b) disconnect the battery cells from the battery management system only during a failure event, (c) separate the driving of balancing resistors into first and second stages, with the first stage comprising cell balancing control and the second stage comprising cell balancing with reverse voltage protection and (d) provide single stage reverse voltage protection to limit or effectively eliminate an electrical conduction path through a low impedance balancing circuit.

[0006] US20140320065A1 discloses about a battery management system that monitors and controls the charging and discharging of a battery pack in the most versatile way at the block level with little dissipative loss but fast balancing is disclosed. The system has capability of using blocks of cells using different chemistry in the same battery pack. Such versatility makes it very useful for usage with erratic grid conditions, solar, wind and other natural energy sources for charging the battery.

[0007] Conventionally, many means are available for diagnosing and servicing EV batteries. However, the cited invention lacks in fully automating the entire diagnostic and servicing process, requiring manual intervention for tasks such as battery identification and maintenance. Existing systems are often limited to basic functions such as charging or simple fault detection, which do not address the full range of maintenance needs including diagnostics, cleaning, electrolyte management, and precise servicing of various battery types.

[0008] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that is capable of fully automating the diagnostic, servicing, and maintenance processes for EV batteries. The system should be designed to handle a variety of battery sizes and types for ensuring versatility and scalability for use in different types of EVs, thereby improving efficiency, safety, and performance of batteries while reducing downtime and human error.

OBJECTS OF THE INVENTION

[0009] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0010] An object of the present invention is to develop a system that is capable of diagnosing and servicing electric vehicle batteries without requiring manual intervention.

[0011] Another object of the present invention is to develop a system that is capable of ensuring precise and safe handling of electric vehicle batteries during inspection, maintenance, and charging processes.

[0012] Another object of the present invention is to develop a system that is capable of automate the identification and classification of battery types to ensure compatibility with diagnostic and servicing routines.

[0013] Another object of the present invention is to develop a system that is capable of supporting continuous transition of batteries to appropriate operational zones based on real-time diagnostic outcomes.

[0014] Another object of the present invention is to develop a system that is capable of enabling energy management during battery charging, including dynamic switching to alternative power sources in case of voltage irregularities.

[0015] Yet another object of the present invention is to develop a system that is capable of facilitating eco-friendly battery servicing that aimed at maintaining battery health.

[0016] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0017] The present invention relates to an automated electric vehicle (EV) battery diagnostic and servicing system for enabling continuous, hands-free handling, positioning, maintenance and processing of batteries, thereby reducing human intervention and improving operational efficiency during servicing of the batteries.

[0018] According to an embodiment of the present invention, an automated electric vehicle (EV) battery diagnostic and servicing system, comprises of a housing equipped with a hinged door and incorporates a rectangular platform on its base, configured to support an EV during diagnostic and servicing procedures. The platform is height-adjustable via multiple hydraulic pistons located between the housing and the platform for allowing ergonomic access to the battery compartment.

[0019] An artificial intelligence-based imaging unit, in conjunction with multiple ultrasonic sensors embedded within the housing, captures and processes images of the internal environment to detect the vehicle’s wheel position and dimensions. This positional data is used to guide a motorized sliding unit mounted at the edges of the platform, which controls the positioning of one or more wheel locking assemblies. These assemblies are dynamically adjusted by a microcontroller, which also integrates an Optical Character Recognition (OCR) module. The OCR module scans battery labels to detect and classify battery type based on visible textual data.

[0020] A motorized dual-axis slider is mounted on the ceiling of the housing and is controlled by the microcontroller. The slider carries a tool chamber equipped with multiple diagnostic and servicing tools, including Motorized wrenches on extendable rods with motorized ball-and-socket joints for loosening or tightening terminal connectors and battery fastening screws, A battery gravity meter for measuring electrolyte specific gravity, providing insight into the charge condition and battery health, A motorized clamping unit for securely gripping the battery during diagnostics and removal and a level sensor for measuring the levels of sulfuric acid and distilled water inside the battery cells.

[0021] Multiple telescopically operated grippers within the housing, controlled by the microcontroller, that transfer the battery from the vehicle to a sliding track assembly. This track features a battery-carrying plate that guides the battery toward either a charging terminal section or a repair and maintenance section based on diagnostic results. The plate includes motorized clippers connected to hydraulic bars and mounted on motorized ball-and-socket joints to accommodate batteries of varying sizes and enable precise positioning.

[0022] The charging terminal section houses multiple charging terminals, each capable of supporting different battery types through adaptive connectors. Each terminal includes an LED indicator array for visual charge status feedback, a digital energy meter for tracking energy usage, and an IoT-enabled database for storing charge data for billing, analytics, and predictive maintenance. A voltmeter embedded in the charging terminals monitors incoming electrical parameters. If any unsafe fluctuation is detected, the microcontroller automatically switches the power supply to an integrated solar or battery backup unit to ensure uninterrupted charging.

[0023] The maintenance section includes a multi-sectioned container holding purified water and sulfuric acid, which are mixed in a motorized vessel via iris-lids equipped conduits. The resulting neutralizing solution is dispensed over the battery through an electronic sprayer for cleaning or maintenance purposes. Additionally, a motorized disc equipped with bristles is connected to a telescopically operated L-shaped pole. Controlled by the microcontroller, this unit extends and rotates to scrub the battery surface effectively and safely. A digital display unit within the housing presents real-time operational data including voltage, charge levels, estimated charging time, maintenance recommendations, and billing confirmations. The entire system is powered by an onboard battery, ensuring that all electronic and electromechanical components function smoothly and efficiently.

[0024] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a perspective view of an automated electric vehicle (EV) battery diagnostic and servicing system.

DETAILED DESCRIPTION OF THE INVENTION

[0026] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0027] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0028] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0029] The present invention relates to an automated electric vehicle (EV) battery diagnostic and servicing system that provide a sustainable battery management solution with real-time monitoring, adaptive energy control, and automated maintenance processes that enhance battery lifespan, performance, and user transparency.

[0030] Referring to Figure 1, a perspective view of an automated electric vehicle (EV) battery diagnostic and servicing system is illustrated, comprising a housing 101 installed with a hinged door 102, a rectangular platform 103 is provided on base of the housing 101, an artificial intelligence-based imaging unit 104 installed inside the housing 101, a motorized sliding unit 105 mounted at edges of the platform 103, one or more wheel locking assembly 106 attached with the sliding unit 105, a motorized dual-axis slider 107 mounted at ceiling of the housing 101, a tool chamber 108 attached with the slider 107, a set of motorized wrenches 109 individually mounted on extendable rods 110, coupled with motorized ball-and-socket joints 111, a battery gravity meter 112, a motorized clamping unit 113, a level sensor 114, plurality of telescopically operated grippers 115 provided inside the housing 101.

[0031] Figure 1 further illustrates a sliding track assembly 116 installed in continuation to the platform 103, a battery-carrying plate 117 to receive the battery, a plurality of charging terminals 118 provided within the housing 101, a multi-sectioned container 119 provided on the maintenance section connected to a mixing vessel 120 via conduits 121, a motorized stirrer 122 provided inside the vessel 120, an electronic sprayer 123 connected with the vessel 120, a motorized disc 124 installed with the maintenance section via a L-shaped telescopically operated pole 125 and equipped with plurality of bristles 126, a digital display unit 127 is provided inside the housing 101 and multiple hydraulic pistons 128 are embedded between base of the housing 101 and the platform 103.

[0032] The system disclosed herein includes a housing 101 that serves as the central enclosure for the entire system. The housing 101 is equipped with a hinged door 102, which is designed to open wide enough to accommodate a range of electric vehicles (EVs), including compact cars, sedans, and lightweight commercial EVs. The hinged door 102 facilitates easy ingress and egress of vehicles into the housing 101 for ensuring minimal manual effort and seamless automation.

[0033] Positioned at the base of the housing 101 is a rectangular platform 103, which functions as the main support bed for the electric vehicle during diagnostic and servicing procedures. This platform 103 is dimensioned to accommodate vehicles of varying sizes and wheelbases. It is designed with structural reinforcements to bear the weight of the EV while also providing a stable, vibration-free base for accurate diagnostic tasks. For example, whether the vehicle is a compact EV or a larger model, the platform 103 provides consistent support and positioning.

[0034] Beneath this platform 103, multiple hydraulic pistons 128 are embedded, which when activated, raise or lower the height of the platform 103 in a smooth and controlled manner. The vertical mobility of the platform 103 allows the platform 103 to adjust the working height to suit the specific servicing task at hand, in view of offering ergonomic access to the EV’s battery compartment.

[0035] The adjustable height addresses a key challenge in EV battery servicing variations in battery positioning and undercarriage clearance across different models. For example, in some EVs, the battery is mounted flat on the chassis base, while in others, it may be embedded deeper into a reinforced compartment. By positioning the EV at an optimal height, the system reduces mechanical strain on servicing components, prevent potential misalignment of tools, and minimize the risk of error during delicate operations. Moreover, the pistons 128 are actuated in a synchronized manner to maintain a level surface during lifting, or they are controlled independently to slightly tilt the platform 103 if needed for specialized tasks. For example, if battery removal requires gravity-assisted sliding, the platform 103 is tilted backward to allow easier disengagement and transfer of the battery.

[0036] An artificial intelligence-based imaging unit 104, installed within the internal structure of the housing 101 for facilitating visual and spatial awareness. The imaging unit 104 operates in synergy with a plurality of ultrasonic sensors also embedded inside the housing 101, forming a hybrid sensory framework that captures both visual and spatial data necessary for precise vehicle positioning and measurement.

[0037] The AI-based imaging unit 104 is equipped with high-resolution cameras, often using stereoscopic or wide-angle lenses integrated with a processor, capable of capturing multiple images of the vehicle and its surroundings from various angles. The imaging unit 104 monitor the entire internal environment, especially the platform 103 and the wheels of the incoming EV. The imaging unit 104 utilizes machine learning protocols trained to recognize vehicles, identify wheel types, and assess spatial positioning based on image data and contextual markers. The processor carries out a sequence of image processing operations including pre-processing, feature extraction, and classification by utilizing artificial intelligence and machine learning protocols.

[0038] Working in coordination with the imaging unit 104, ultrasonic sensors are positioned along the periphery of the platform 103 and around the interior structure of the housing 101. These sensors emit high-frequency sound waves and detect their reflections to accurately measure distances between the vehicle and structural boundaries, including the floor, walls, and wheel guides. This dual-sensor arrangement visual imaging and ultrasonic echo-location enables the system to create a real-time three-dimensional map of the vehicle’s position within the housing 101.

[0039] As a vehicle enters and positions itself on the platform 103, the AI imaging unit 104, with the aid of the ultrasonic sensors, immediately begins scanning the vehicle’s wheelbase and chassis alignment. The imaging unit 104 captures images from multiple angles to precisely identify the position and orientation of all four wheels on the platform 103. For example, if the system detects that the vehicle's front wheels are slightly misaligned with respect to the locking points, it calculates the offset and relay corrective instructions to the microcontroller.

[0040] Furthermore, the imaging unit 104 is capable of extracting dimensional data about the wheels, such as diameter, width, and distance between the wheels (wheelbase). This capability is essential because electric vehicles come in various configurations. For example, a compact EV has significantly smaller wheels than a utility-oriented EV. The system recognizes these differences to dynamically adjust the positioning of downstream components.

[0041] In addition to physical measurements, the imaging unit 104 also detect anomalies. For example, if a vehicle is improperly positioned perhaps only partially on the platform 103 or skewed at an angle, the system identifies this misalignment and alert the operator thereby eliminating reliance on human precision during vehicle parking.

[0042] Another example of the imaging unit’s versatility is its ability to perform under various lighting and environmental conditions. Equipped with infrared vision and thermal imaging capabilities, the imaging unit 104 function reliably in low-light scenarios or detect excess heat signatures that indicate battery overheating or system faults before diagnostic procedures begin.

[0043] A motorized sliding unit 105 is mounted along the edges of the platform 103 where the electric vehicle is positioned. This unit is specifically designed to dynamically adjust the position of one or more wheel locking assemblies, which are integral for securing the EV firmly during battery removal processes.

[0044] The motorized sliding unit 105 comprises linear actuators or servo-driven rails installed along both sides of the platform 103. These actuators allow the attached wheel locking assemblies to move horizontally along the length of the platform 103. The wheel locking assemblies themselves are mechanical structures equipped with gripping or bracing components, such as adjustable clamps or padded stoppers, which engage with the EV’s wheels. These locks are responsible for immobilizing the wheels to ensure zero lateral or longitudinal movement during precision operations like unscrewing battery fasteners.

[0045] Crucially, each of these wheel locking assemblies is actuated by a microcontroller, which acts as the local processing unit controlling their movement and locking behavior. This microcontroller is wirelessly connected to the AI-based imaging unit 104. Based on real-time data received from the imaging unit 104, including the position, size, and alignment of the vehicle's wheels, the microcontroller calculates the exact placement required for each locking assembly 106. For example, if a vehicle with a longer wheelbase is detected, the system adjusts the rear locks further apart compared to a smaller vehicle. This real-time feedback loop between the imaging unit 104 and the microcontroller ensures that the wheel locks automatically position themselves to align with the exact wheel location and diameter, completely removing the need for manual input or adjustment.

[0046] An Optical Character Recognition (OCR) module is integrated within the same microcontroller. OCR is a technology that allows the system to interpret and digitize text from images. Herein, the OCR module is synchronized with the imaging unit 104 to scan the external labels, tags, or engravings on the surface of the battery or battery compartment once the vehicle is locked in place. These labels often contain crucial information such as battery type (e.g., lithium-ion, nickel-metal hydride), manufacturer, voltage rating, serial numbers, or maintenance codes.

[0047] For example, the OCR module read a label such as "LG Chem 350V 60kWh Li-ion" printed on a battery pack. The system immediately processes this text, classifies the battery type, and references an internal or cloud-based database to determine the most suitable diagnostic routine, clamping strategy, and charging profile. This classification step is vital as different battery chemistries and specifications require distinct handling procedures such as lithium-ion batteries are serviced with precise voltage monitoring, whereas lead-acid units require fluid top-ups and gravity measurements.

[0048] Additionally, by integrating OCR into the vehicle setup phase, the system avoids dependency on manual database entry or pre-loaded vehicle data, making the servicing process completely adaptive and autonomous. Even if a new or lesser-known EV model enters the housing 101, the system identifies its battery type by simply analyzing the surface label in view of allowing the rest of the servicing logic to proceed accordingly.

[0049] A motorized dual-axis slider 107 mounted at the ceiling of the housing 101 equipped with tool chamber 108 that houses various automated diagnostic and maintenance tools. The slider 107 aids to maximize operational efficiency and spatial accessibility within the housing 101 for enabling the tools to reach any area of the electric vehicle from above without obstruction. Its movement is actuated by the microcontroller, which orchestrates the real-time positioning based on commands issued from the central diagnostic system and imaging unit 104.

[0050] The dual-axis slider 107 operates using motorized rails along the X- and Y-axes, allowing the tool chamber 108 to travel both laterally and longitudinally across the ceiling of the housing 101. This two-dimensional freedom of motion enables the tool chamber 108 to be precisely aligned over the battery compartment or specific servicing points on the vehicle. Once aligned, the chamber 108 lower its integrated tools via extendable arms, making it possible to interact with components positioned at various depths and angles.

[0051] Within this tool chamber 108, a suite of specialized components is mounted, each playing a vital role in automating the traditionally manual and labor-intensive processes of EV battery servicing: The tools are:

A. Motorized Wrenches 109 with Ball-and-Socket Articulation: These wrenches 109 are mounted on extendable rods 110, each of which is connected via a motorized ball-and-socket joint. This joint offers multi-axis articulation, enabling the wrenches 109 head to rotate, pivot, and tilt with fine-grained angular precision. The extendable rods 110 adjust their length to reach deeply recessed or obstructed fastening points. These wrenches 109 are pre-fed to automatically loosen or tighten screws, bolts, or terminal connectors associated with battery mounts, cable clamps, or seat structures.

[0052] For example, if a vehicle has a battery secured under the chassis with torx-head bolts, the imaging unit 104 identifies these points, and the tool chamber 108 aligns a wrenches 109 directly above them. The wrenches 109 arm extends, the joint angles to match the bolt orientation, and the wrenches 109 activates with precise torque to remove or fasten the fasteners without damaging the components. This ensures uniform torque application, reducing the chances of over-tightening or thread damage.

B. Battery Gravity Meter: The gravity meter 112 mounted on an articulated rod 110 and is used to measure the specific gravity of the electrolyte fluid in lead-acid battery types. This measurement indicates the charge level and health of individual battery cells. The tool lowers its sampling probe into the fluid reservoir and uses refractometer or float-type means to determine the electrolyte density.

[0053] For example, in a EV battery with visible cell ports, the tool arm extends the gravity meter 112 into each cell opening. The data collected helps identify undercharged or sulfated cells that require repair or equalization. This functionality enables non-invasive, fully automated state-of-health (SOH) diagnostics, which are critical for predictive maintenance and operational longevity.

C. Motorized Clamping Unit: The clamping unit 113 is designed for securely gripping and stabilizing the battery pack during diagnostic, removal, or transport operations. Mounted similarly on an extendable rod 110 with a ball-and-socket joint, the clamp articulates to align with the battery's center of gravity and physical contours. Once aligned, it activates with controlled pressure to prevent slippage or damage.

[0054] For example, if the system determines the battery is a heavy, modular lithium-ion unit with side lifting lugs, the clamp aligns with these lugs, extends, grips them using padded jaws, and holds the battery stable while diagnostic tests or removal procedures are carried out. This eliminates the need for human handling, enhancing safety and consistency.

D. Level Sensor for Acid and Water Detection: The level sensor 114 is used to measure the levels of sulfuric acid and distilled water inside individual battery cells, which is essential for the maintenance of flooded lead-acid batteries. The level sensor 114 is similarly mounted on an extendable rod 110, which precisely positions it above open cell ports. Once deployed, the level sensor 114 uses ultrasonic or capacitance-based level detection to determine fluid levels inside the battery.

[0055] For example, in a battery with multiple cell chambers, the level sensor 114 autonomously checks each chamber’s electrolyte volume, detect evaporation or leakage, and generate reports on which cells need refilling. This is particularly important in older battery technologies where regular fluid maintenance is needed to ensure efficient charge/discharge cycles and prevent internal damage.

[0056] The motorized ball-and-socket joints 111 combined with extendable rods 110 provides 6 degrees of freedom, closely mimicking a human arm’s dexterity but with far greater precision, repeatability, and strength. This not only enhances operational versatility but also reduces human error and improves safety, making it a groundbreaking solution for fully automated electric vehicle battery servicing.

[0057] A plurality of telescopically operated grippers 115 housed within the housing 101 to safely and efficiently handle battery packs during servicing. These grippers 115 are directly actuated and controlled by the microcontroller, which receives real-time commands based on diagnostic results, vehicle specifications, and spatial analysis from the imaging unit 104. Their primary function is to extract, lift, and transfer the battery from the vehicle platform 103 to a sliding track assembly 116, which acts as a guided rail pathway to direct the battery to the appropriate station either for charging or for repair and maintenance, depending on the battery’s evaluated condition.

[0058] Each gripper is telescopically extendable which means that the grippers 115 expand or retract its reach based on the size, position, and placement depth of the battery. This extension capability enables it to adapt to a variety of electric vehicles, from compact cars with small under-seat batteries to SUVs with large, heavy floor-mounted battery packs. The microcontroller governs the actuation by computing optimal approach vectors and distances, thus ensuring a firm yet non-damaging grasp on the battery body.

[0059] Once the grippers 115 engage with the battery, they lift and position it onto a specialized battery-carrying plate 117, which is mounted on motorized sliding track assembly 116 installed as a continuation of the main platform 103. This sliding track acts like a conveyor rail but with control and positioning features, allowing it to redirect the battery to multiple destinations within the housing 101. The plate 117 itself is a base, equipped with motorized clippers that adjust automatically to securely clamp batteries of varying dimensions, widths, and structural profiles. These clippers are powered by hydraulic bars that allow not just clamping force, but also multi-directional angular adjustment, facilitated through motorized ball-and-socket joints 111.

[0060] For example, suppose a user drives in with an EV that contains a flat-pack lithium-ion battery with asymmetrical dimensions. The imaging unit 104 first measures the battery’s footprint, and the grippers 115 extend telescopically to match the required depth. They lock onto standard pickup points (such as integrated lifting brackets or housing 101 ribs), lift the battery cleanly, and then move it horizontally to the sliding plate 117. The motorized clippers on the plate 117 then adjust their jaws to match the dimensions, gripping firmly to prevent vibration or slippage during transport.

[0061] Once in motion, the sliding plate 117 glides over the track assembly 116, following a pre-fed route. The imaging unit 104 guides for ensuring precise arrival at the intended location, aligning the battery’s ports and connectors with the respective service modules. The motorized ball-and-socket joints 111 enable the plate 117 to slightly tilt or rotate the battery if a connector misalignment is detected, providing the exact positional flexibility needed for continuous interfacing with downstream components such as charging terminals or fluid service modules.

[0062] A plurality of charging terminals 118 integrated within the dedicated charging terminal section of the housing 101 that accommodate a wide variety of battery types and electrical specifications, making the system highly versatile and adaptable to the diverse battery technologies found across different electric vehicle (EV) models. Each charging terminal operates as a modular interface station, equipped with a set of adaptive connectors that automatically adjust and lock into place based on the shape, size, and terminal configuration of the battery being serviced. This allows for a continuous electrical connection whether the battery uses top-mounted posts, side terminals, or proprietary connectors typically found in high-performance EV batteries.

[0063] The adaptive connectors are mechanically and electronically configured to detect the battery’s terminal layout through feedback from the imaging unit 104 and the microcontroller. These connectors are retractable or adjustable prongs, clamps, or magnetic coupling interfaces, and are actuated by mini servo motors controlled by the microcontroller. For example, if a lithium-ion battery with dual-pin connectors is placed into the charging bay, the terminal identifies the connection type via OCR analysis or pre-recorded battery profiles, and the adaptive connector shifts into the appropriate configuration to engage securely. This eliminates the need for manual intervention or reconfiguration, significantly streamlining the charging process for various battery chemistries such as Li-ion, NiMH, lead-acid, or solid-state cells.

[0064] Multiple LEDs (Light Emitting Diode) indicator arrays are mounted visibly near or on the terminal interface. These multicolor LED strips provide real-time, intuitive visual feedback on the charging progress and battery status using universally recognizable color codes such as red for critical low battery, amber for ongoing charging, green for fully charged, and blue or white for idle or standby.

[0065] Each terminal is equipped with a digital energy meter, an electronic device embedded within each unit to measure the precise amount of electrical energy delivered to each battery during a charging session. This energy meter records not only the kWh consumed, but also logs parameters like charging duration, peak and average current draw, voltage fluctuations, and charge completion time. These detailed records are not stored locally but are instead transmitted in real-time to a cloud-connected IoT (Internet of Things) database. This connectivity enables a host of functionalities including:

• User Billing: Fleet operators, EV owners, or rental services are billed accurately based on energy consumed per charging session.
• Predictive Maintenance Forecasting: By analyzing charging patterns and energy inefficiencies (e.g., longer-than-usual charging times or inconsistent voltage draw), the system predict battery degradation or impending faults, helping users plan battery replacements or service intervals proactively.
• Charging Behavior Analytics: The stored data helps in understanding usage patterns, such as average time-of-day charging, preferred terminal use, and battery performance over time, which is visualized in dashboards or reports for optimization.

[0066] A voltmeter embedded in each charging terminal aids in the safety, reliability, and continuity of the system. The voltmeter is not just a conventional measuring instrument; rather, it functions as a real-time electrical monitoring module that continually scans and records the incoming voltage levels from the primary power source feeding the charging terminals 118. This real-time voltage tracking is essential in EV battery charging, where even minor deviations outside the optimal range negatively affect battery health, trigger overvoltage protection circuits, or cause charging interruptions.

[0067] The voltmeter is operatively linked with the microcontroller that receives continuous digital input signals from the voltmeter and compares them against predefined safety thresholds. For example, if the standard input voltage is expected to be 230V AC, but due to an external grid anomaly or power line disturbance the voltage drops below 200V or spikes above 250V, the microcontroller immediately detects the voltage fluctuation. These fluctuations, if unchecked, damage delicate onboard electronics, affect adaptive charging behavior, or lead to overcharging or undercharging of connected batteries, thereby reducing their lifespan.

[0068] To handle such cases, the system is pre-fed with an automatic fallback means. Upon detecting any instability or unsafe voltage condition, the microcontroller instantly initiates a power source switching protocol. This action triggers a continuous transition from the unstable grid-based power supply to one of two alternative sources: a solar power unit or a battery backup unit, both of which are integrated within the housing 101. This ensures uninterrupted power delivery to the charging terminals 118, diagnostic tools, and system control units even in the event of a complete power outage or extreme fluctuation.

[0069] The solar power unit typically consists of photovoltaic panels (mounted either on the housing 101's roof or externally) connected to an inverter and energy management. This solar unit, during daylight hours, serves as a renewable and sustainable energy source. If the system detects voltage instability during the daytime, it prefers switching to this solar backup, allowing operations to continue in an eco-friendly and cost-effective manner. In contrast, the battery backup unit, often comprising high-capacity lithium-ion or lead-acid cells, serves as an emergency source during night operations or when solar output is insufficient.

[0070] A multi-sectioned container 119 is incorporated in the housing 101 for maintaining and servicing the electrolyte levels of lead-acid batteries, or potentially other types of batteries that require fluid-based maintenance, such as some hybrid or older battery. This container 119 is specifically designed to hold two essential chemicals: purified water and sulfuric acid solution, both of which are integral to the battery's operation and health. The container 119 is divided into separate compartments to safely store each of these liquids, preventing any accidental mixing or contamination. The water and sulfuric acid are each stored in dedicated sections, and their amounts are carefully controlled by the system to ensure precise and safe dispensing during battery servicing.

[0071] The container 119 is connected to a mixing vessel 120 via conduits 121 having iris lids to securely transfer the liquid solutions from the storage compartments to the mixing vessel 120. Upon receiving the necessary commands, the iris lids of the conduits 121 open to allow for the controlled discharge of the purified water and sulfuric acid solution into the mixing vessel 120. The precise ratio of water and sulfuric acid is critical, as it determines the final electrolyte composition needed for specific battery types. The system automatically adjusts the flow based on predefined formulas or real-time analysis of the battery’s condition for ensuring the correct proportions for neutralization.

[0072] Once the water and sulfuric acid have entered the mixing vessel 120, a motorized stirrer 122 inside the vessel 120 is activated. This stirrer 122 is designed to vigorously agitate the mixture to ensure that the two components are thoroughly blended to form a neutralizing solution. This solution aids in reconditioning the electrolyte of the battery, particularly in lead-acid batteries, where electrolyte composition degrades over time due to sulfation (the formation of lead sulfate crystals on the battery plates), or electrolyte evaporation. The neutralizing solution helps restore proper electrolyte levels and balance, which is essential for maximizing battery performance, extending lifespan, and ensuring that the battery is charged and discharged efficiently.

[0073] After the neutralizing solution is properly mixed, the system uses an electronic sprayer 123 connected to the mixing vessel 120 to dispense the solution directly over the battery's cells. This sprayer 123 is controlled by the microcontroller, which ensures that the solution is evenly applied to the battery cells without overfilling or spilling. The sprayer 123 is precisely aimed and adjusted, as the microcontroller calculate the exact amount of solution required based on the battery’s size, condition, and diagnostic results.

[0074] A motorized disc 124 is mounted on an L-shaped telescopically operated pole 125 installed within the housing 101 that is actuated by the microcontroller and the extension and retraction are controlled by a pneumatic unit installed with the pole 125. This allows for precise movement and ensures that the disc 124 is positioned at the ideal angle and distance from the battery's surface.

[0075] Once the pole 125 is adjusted, the microcontroller activates the motorized disc 124, which is designed to rotate rapidly for cleaning purposes. The disc 124 is equipped with a plurality of bristles 126, typically made from abrasive, but non-damaging materials such as synthetic fibers or soft nylon. These bristles 126 are arranged in a circular pattern, designed to cover a wide surface area during the rotation. As the disc 124 rotates, the bristles 126 gently scrub the battery’s external surface, particularly focusing on the terminals, connectors, and other high-contact areas where dirt, corrosion, and debris tend to accumulate. The bristles 126 ensure that no harsh scraping or damaging actions occur, as they are specifically chosen to be abrasive enough to remove corrosion or dirt, but gentle enough not to damage delicate components or coatings on the battery.

[0076] The actuation of the pole 125 and disc 124 is coordinated by the microcontroller, which uses data from the diagnostic sensors or battery condition reports to determine when cleaning is necessary. For example, if a lead-acid battery is found to have signs of corrosion at its terminals, or if the visual inspection through the imaging unit 104 identifies grime accumulation, the microcontroller automatically triggers the cleaning means. The cleaning operation is typically carried out before or during the diagnostic process to ensure that the battery’s condition is thoroughly evaluated and cleaned, preventing any interference from surface contaminants.

[0077] For example, consider a scenario in an EV servicing station, where a lead-acid battery is detected to have corroded terminals. The microcontroller, after analyzing the diagnostic results, activates the telescoping pole 125 to extend and position the rotating disc 124 at an optimal distance from the battery terminals. The bristles 126 of the disc 124 then begin their scrubbing motion. The bristles 126 apply moderate pressure to ensure effective cleaning while ensuring the bristles 126 do not exert excessive force that could damage the battery casing. As the disc 124 spins, it removes any build-up of corrosion, dirt, or grime from the battery terminals, improving electrical contact and promoting better charge/discharge performance.

[0078] A digital display unit 127 is installed within the housing 101 for presenting critical information about the battery’s status and the ongoing servicing process. The display unit 127 is integrated with the microcontroller and other diagnostic components, enabling it to visually present real-time data related to the battery being serviced. Some of the key data points shown on the display include battery voltage, which indicates the current electrical potential difference between the battery terminals; charge percentage, representing the current charge level as a percentage of the battery’s total capacity; and remaining charging time, which estimates how much longer time is taken for the battery to reach full charge based on current charging conditions. These metrics provide valuable insights to users or technicians, allowing them to monitor the status of the battery and make informed decisions regarding its service or further actions.

[0079] Additionally, the digital display unit 127 is designed to provide service recommendations and payment confirmations. Based on the diagnostic results, the system displays suggestions for further maintenance or reconditioning, such as a recommendation for electrolyte replacement or terminal cleaning, depending on the battery's condition. For example, if a lead-acid battery shows signs of sulfation or low electrolyte levels, the display prompt the technician to initiate electrolyte restoration procedures or schedule a more in-depth inspection. The unit also aids in user interaction by providing payment confirmations once a service transaction is completed. This is particularly useful in automated service stations or charging stations where users pay for services via a digital interface, with the display confirming that the payment was successful and the service cycle has been completed.

[0080] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) An automated EV battery diagnostic and servicing system, comprising:

i) a housing 101 installed with a hinged door 102 developed to accommodate an EV (electric vehicle), wherein a rectangular platform 103 is provided on base of said housing 101, configured to receive and support said vehicle positioned thereon for diagnostics;
ii) an artificial intelligence-based imaging unit 104 installed inside said housing 101 and paired with plurality of ultrasonic sensors provide inside said housing 101 to detect exact positioning of wheels of said vehicle over said platform 103, along with dimensions of said wheels;
iii) a motorized sliding unit 105 mounted at edges of said platform 103, configured to enable adjustable positioning of one or more wheel locking assembly 106 attached with said sliding unit 105, wherein each wheel locking assembly 106 is dynamically actuated by a microcontroller linked with said imaging unit 104 for positional adjustment according to dimensions of wheels of said vehicle;
iv) a motorized dual-axis slider 107 mounted at ceiling of said housing 101 actuated by said microcontroller to translate a tool chamber 108 attached with said slider 107, wherein said tool chamber 108 comprises a plurality of diagnostic and maintenance components, including:

a. a set of motorized wrenches 109 configured to automatically loosen or tighten terminal connectors and fastening screws securing battery or seat structure;
b. a battery gravity meter 112 for automated measurement of electrolyte specific gravity, configured to provide charge condition and health indicators;
c. a motorized clamping unit 113 adapted to securely grip and hold the battery in position during diagnostic and removal operations; and
d. a level sensor 114, configured to measure levels of sulfuric acid and distilled water within the battery cells.

v) plurality of telescopically operated grippers 115 provided inside said housing 101 that are actuated by said microcontroller for transfer of said battery over a sliding track assembly 116 installed in continuation to said platform 103, wherein said sliding track assembly 116 is configured with a battery-carrying plate 117 to receive said battery, and said plate 117 is selectively guided toward either a charging terminal section or a repair and maintenance section provided inside said section, based on the results of automated battery diagnostics;
vi) plurality of charging terminals 118 provided within said charging terminal section, each terminal configured to support multiple battery types and specifications, wherein each charging terminal is equipped with adaptive connectors, designed to interface with different terminal types;
vii) a voltmeter embedded in charging terminals 118 and configured to continuously monitor electrical supply parameters, said voltmeter being operatively connected to said microcontroller to detect voltage fluctuations, particularly from charging terminal's power input, wherein upon detecting an instability or unsafe fluctuation said microcontroller automatically switches power supply source to a solar power unit and/or battery backup unit integrated within said housing 101;
viii) a multi-sectioned container 119 provided on said maintenance section, stored with purified water and sulfuric acid solution, and connected to a mixing vessel 120 via iris lid conduits 121, wherein said conduits 121 discharge water and sulfuric acid solution into said vessel 120, followed by actuation of a motorized stirrer 122 provided inside said vessel 120 to form a neutralizing solution, that is dispensed over said battery via an electronic sprayer 123 connected with said vessel 120; and
ix) a motorized disc 124 installed with said maintenance section via a L-shaped telescopically operated pole 125 and equipped with plurality of bristles 126, wherein said microcontroller actuates said poke to extend, followed by actuation of said disc 124 to rotate for scrubbing said battery via said bristles 126, enabling safe and effective cleaning without manual handling.

2) The system as claimed in claim 1, wherein each of said aforementioned diagnostic and maintenance components are individually mounted on extendable rods 110 coupled with motorized ball-and-socket joints 111, allowing multi-axis movement and angle adjustment for articulation.

3) The system as claimed in claim 1, wherein multiple hydraulic pistons 128 are embedded between base of said housing 101 and said platform 103, configured to raise or lower height of said platform 103 to provide ergonomic and accurate access to the battery.

4) The system as claimed in claim 1, wherein an OCR (Optical Character Recognition) module is integrated with said microcontroller and synced with said imaging unit 104 to detect and classify the battery type based on surface text and label data.

5) The system as claimed in claim 1, wherein said sliding plate 117 comprises of motorized clippers adapted to securely hold a battery of varying dimensions, said clamping unit 113 are connected to hydraulic bars and mounted on motorized ball-and-socket joints 111, allowing multidirectional angular and linear movement for precise placement and orientation.

6) The system as claimed in claim 1, wherein a digital display unit 127 is provided inside said housing 101, configured to visually present real-time data including battery voltage, charge percentage, remaining charging time, service recommendations, and payment confirmations.

7) The system as claimed in claim 1, wherein each charging terminals 118 is associated with an LED indicator array, configured to provide intuitive visual feedback on battery charge status through color-coded illumination.

8) The system as claimed in claim 1, wherein each charging terminal comprises a digital energy meter, configured to track amount of electrical energy consumed per battery, storing energy usage data in a cloud-connected IoT database for user billing, predictive maintenance forecasting, and charging behavior analytics.

9) The system as claimed in claim 1, wherein a battery is associated with said system for supplying power to electrical and electronically operated components associated with said system.