Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated electric vehicle battery maintenance and optimization system that is capable of enhancing battery performance, ensuring reliable maintenance, extending service life, and providing secure, traceable records of all maintenance activities.

BACKGROUND OF THE INVENTION

[0002] Efficient energy storage management is essential for maximizing the performance, reliability, and lifespan of modern electric transportation. Proper upkeep and optimization of energy units ensure consistent power delivery, extend operational durability, and enhance driving range, contributing to cost-effective and sustainable mobility. In real-world scenarios, the practices support daily commuting, long-distance travel, and commercial transportation by reducing downtime and improving efficiency. Additionally, the approaches also promote environmental benefits through reduced energy wastage and emissions, while enabling safer, more reliable, and high-performing electric mobility solutions for urban, suburban, and industrial applications.

[0003] The traditional approaches to managing electric vehicle energy storage rely on periodic inspections, manual diagnostics, and generalized maintenance schedules. The methods fail to account for real-time usage patterns, environmental conditions, and driving behaviour, resulting in uneven performance and reduced lifespan. Limited monitoring accuracy leads to inefficient charging habits and inconsistent power delivery. Additionally, the absence of predictive evaluation restricts early fault identification and timely intervention. The limitations decrease operational reliability, increase long-term costs, and hinder optimal energy utilization, making the methods challenging to achieve sustained efficiency and dependable electric mobility performance.

[0004] US8970173B2 discloses a method of setting the operational mode of an electric vehicle is provided, where the operational mode is selected from a plurality of operational modes that include at least a Battery Life mode and a Standard mode, wherein the Battery Life mode is configured to select operating and charging parameters that emphasize battery health and battery life over vehicle range and/or vehicle performance. The system includes a thermal management system for maintaining the vehicle's battery pack to within any of a plurality of temperature ranges, and a charging system for charging the vehicle's battery pack to any of a plurality of minimum and maximum SOC levels and at any of a plurality of charging rates.

[0005] US5461298A discloses a system and method for automatically docking a vehicle with respect to a charge station. First, the system and method automatically aligns a charge probe arm with respect to a vehicle charge port. Next, the system and method automatically establish a power connection between the probe and port. Next, charging power is delivered through the connection to charge the electric power storage devices of the vehicle. Finally, the charging connection is automatically disconnected by disconnecting the probe from the port once charging is completed.

[0006] Conventionally, many systems disclosed in the prior art provide a means for maintaining electric vehicle power units that rely on periodic inspections, manual diagnostics, and fixed service schedules. However, these existing systems are time-intensive, inconsistent, and reactive, resulting in uneven performance and reduced lifespan. Moreover, the reliance also limits predictive capability, reduces operational efficiency, and hinders optimal energy utilization in electric mobility applications.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that requires to be capable of continuously supervising electric vehicle energy units, improving operational performance, and ensuring dependable maintenance. Additionally, the developed system also needs to extend service longevity, maintain secure and traceable maintenance records, and support consistent efficiency, reliability, and optimized energy utilization in everyday mobility applications.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system that efficiently maintains and optimizes the performance of electric vehicle batteries.

[0010] Another object of the present invention is to develop a system that extends battery lifespan while ensuring reliable and timely maintenance operations.

[0011] Yet, another object of the present invention is to develop a system that provides secure, traceable records of all battery maintenance activities and allows convenient remote monitoring and scheduling.

[0012] 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

[0013] The present invention relates to an automated electric vehicle battery maintenance and optimization system that is capable of improving battery performance, ensuring precise and timely maintenance, extending battery lifespan, and providing secure, traceable records of all maintenance activities.

[0014] According to an aspect of the present invention, an automated electric vehicle battery maintenance and optimization system, comprising a rectangular platform as an EV (electric vehicle) battery holding base, an electromagnetic clamps around base periphery of the rectangular frame to hold EV battery, a force sensor into each clamp and upon detection of a deviation in force indicating loosening, the magnetic field of the respective clamp is increased to restore clamping, a plurality of sensors at a proximal tip of an articulated arm to detect lithium and electrolytes levels in the battery, a first chamber with the platform to store fresh lithium compounds, a second chamber with the platform to store high-purity electrolytes, an extraction arrangement with the platform to extract degraded lithium and electrolytes from the battery, a suction unit with the extraction arrangement to suck out the ingredients from the battery into the waste chamber, and a replenishment arrangement with the platform to store and replenish materials for adaptive battery maintenance during lithium and electrolyte replenishment.

[0015] According to another aspect of the present invention, the system further comprises a scissor lift assembly in the frame, for vertical movement of the extraction arrangement for optimal reach and precise alignment with the ports of the battery, a six-bar linkage assembly with the frame to enable horizontal translation of the replenishment module during battery replenishment, a pneumatic cylinder between lower paired crossed arms of the scissor lift assembly to provide the primary linear force to extend or retract the scissor lift assembly, a blockchain-secured cloud-based data with the platform to log battery health metrics, and replenishment events for traceability, a user interface on a computing unit to enable remote monitoring of battery maintenance and also to enable EV operators to schedule battery maintenance schedules without disturbing the vehicle operations, and a plurality of LiDAR sensors in the frame to determine a battery’s dimensions, upon accurate detection of battery’s dimensions, the processing unit triggers the extension, contraction, and locking of the telescopic segments to securely align the frame with the base of the battery.

[0016] 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

[0017] 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 an isometric view of an automated electric vehicle battery maintenance and optimization system.

DETAILED DESCRIPTION OF THE INVENTION

[0018] 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.

[0019] 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.

[0020] 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.

[0021] The present invention relates to an automated electric vehicle battery maintenance and optimization system that is capable of efficiently monitoring battery health, performing material extraction and replenishment, and ensuring precise maintenance scheduling. In addition, the system also enhances battery performance, extends service life, and provides secure traceability of maintenance activities without interrupting vehicle operation.

[0022] Referring to Figure 1, an isometric view of an automated electric vehicle battery maintenance and optimization system is illustrated, comprising a rectangular platform 101, a motorized guiding rail frame 102 integrated around outer periphery of the rectangular platform 101, an electromagnetic clamp 103 mounted at proximal end of telescopic arms 104 integrated around base periphery of the rectangular frame 102, a plurality of sensors 105 embedded at a proximal tip of an articulated arm 106 installed on the platform 101, a suction unit 107 integrated in a waste chamber 108 installed on a scissor lift assembly 109 installed on the platform 101, an extendible conduit 110 attached to the chamber 108, a first chamber 111 and a second sealed chamber 112 installed on a six-bar linkage assembly 113 installed on the platform 101 and a respective flexible conduit 114 integrated with a solenoid valve 115 integrated with the chambers 111, 112.

[0023] The system disclosed herein comprises a rectangular platform 101 configured as an EV (electric vehicle) battery holding base. The rectangular platform 101 forms a rigid, load-bearing base designed to securely support an electric vehicle battery during maintenance operations. The platform 101 is fabricated from high-strength, corrosion-resistant structural metal, optionally reinforced with composite layers for added stiffness. The platform 101 provides a stable, planar surface with precision-machined edges to ensure accurate positioning and long-term durability.

[0024] A plurality of LiDAR (Light Detection and Ranging) sensors is integrated in the frame 102, configured to determine a battery’s dimensions. When activated by a processing unit associated with the system, the LiDAR sensors emit rapid laser pulses toward the battery surface. The emitted light reflects back after striking the battery edges, and the sensor measures the time-of-flight of each pulse. The processing unit processes these return signals to calculate precise distance data, generating a three-dimensional spatial profile of the battery. This dimensional information is used to enable accurate alignment and positioning operations.

[0025] Upon accurate detection of battery’s dimensions, the processing unit triggers a motorized guiding rail frame 102 is integrated around outer periphery of the rectangular platform 101, the frame 102 fabricated of interconnected telescopic segments with integrated linear actuators to securely align the frame 102 with the base of the battery. When activated by the processing unit, the guiding rail frame 102 operates by coordinated extension and retraction of its interconnected telescopic segments.

[0026] The linear actuators apply controlled linear motion to each segment, allowing the frame 102 to expand or contract uniformly along the platform 101 periphery. The telescopic segments slide along precision-guided tracks, maintaining alignment and structural stability. This controlled movement enables accurate positioning and secure fitting of the frame 102 relative to the battery during maintenance operations.

[0027] A plurality of electromagnetic clamps 103 is mounted at a proximal end of telescopic arms 104 integrated around base periphery of the rectangular frame 102 to hold EV battery. Each electromagnetic clamp 103 generates a controlled magnetic field through an internal coil surrounding a ferromagnetic core. The magnetic flux creates an attractive force that securely holds the battery surface without mechanical penetration. The clamp 103 maintains uniform holding pressure across the contact area, reducing localized stress. Upon command from the processing unit, electrical current is modulated to adjust magnetic strength, enabling secure engagement, steady retention during operations, and controlled release once maintenance is completed.

[0028] The telescopic arms 104 consist of multiple nested tubular segments arranged to slide concentrically within one another. Internal linear drive means guide smooth extension and retraction along a fixed axis. Precision bearings and guide channels maintain alignment and prevent lateral play during movement. When actuated by the processing unit, the arms 104 extend to a required reach for positioning and retract compactly afterward, ensuring controlled motion, load stability, and consistent spatial positioning around the battery periphery.

[0029] A force sensor is integrated into each clamp 103 and upon detection of a deviation in force indicating loosening, the magnetic field of the respective clamp 103 is increased to restore clamping. The force sensor operates by converting applied mechanical load into an electrical signal proportional to the detected force. Internally, deformation elements respond to clamping pressure, causing measurable changes in electrical characteristics such as resistance. These changes are continuously monitored by the processing unit to determine applied force levels. If a deviation from a predefined force range is detected, corrective action is initiated to maintain secure and consistent clamping during battery maintenance operations.

[0030] A plurality of sensors 105 is embedded at a proximal tip of an articulated arms 106 to detect lithium and electrolytes levels in the battery. The articulated arms 106 manipulate the plurality of sensor, works internally in the similar manner as the telescopic arm 104 operates.

[0031] The plurality of sensors 105 includes an electrochemical impedance spectroscopy (EIS) sensor, a lithium-ion concentration sensor, an electrolyte composition analyzer for monitoring pH, conductivity, and decomposition, and a temperature sensor to detect temperature.

[0032] The EIS sensor applies a controlled, low-amplitude alternating electrical signal across the battery interface over a range of frequencies. The sensor measures the resulting voltage and current response to determine impedance characteristics. Variations in resistance and reactance are analyzed to infer electrochemical behaviour such as charge transfer efficiency and internal degradation. The resulting impedance profile provides a non-destructive indication of battery health and aging state.

[0033] The lithium ion concentration sensor operates based on selective electrochemical interaction with lithium ions present in the battery environment. Internally, an ion-sensitive element generates an electrical response proportional to lithium ion activity. When engaged, the processing unit interprets changes in this response to determine lithium concentration levels. This measurement enables identification of lithium depletion or imbalance, supporting decisions related to material extraction or replenishment during battery maintenance operations.

[0034] The electrolyte composition analyzer sensor evaluates chemical properties of the electrolyte by monitoring parameters such as pH, ionic conductivity, and byproduct presence. Internally, multiple sensing elements interact with the electrolyte to produce electrical signals corresponding to chemical conditions. Upon activation, the processing unit processes these signals to identify electrolyte degradation, contamination, or decomposition. This analysis supports accurate assessment of electrolyte quality and informs maintenance actions required to restore optimal battery performance.

[0035] The temperature sensor functions by detecting thermal variations and converting them into corresponding electrical signals. Internally, temperature-sensitive materials exhibit predictable changes in electrical characteristics in response to heat. When engaged, the processing unit continuously monitors these changes to determine real-time temperature conditions within the battery environment. Accurate temperature measurement helps identify abnormal thermal behaviour, ensures safe operating conditions, and supports informed control of maintenance processes.

[0036] Upon determination of degradation levels of lithium and electrolytes in the battery by the sensors 105, the processing unit activates an extraction arrangement configured to extract degraded lithium and electrolytes from the battery. The extraction arrangement includes a suction unit 107 integrated in a waste chamber 108, and an extendible conduit 110 attached to the chamber 108.

[0037] The suction unit 107 generates a controlled negative pressure to extract degraded lithium and electrolyte materials from the battery. Internally, a sealed pumping means creates a pressure differential that draws the targeted materials through the conduit 110. Flow regulation ensures steady extraction without disturbing surrounding structures. The suction unit 107 intensity is maintained within predefined limits to enable efficient material removal while preventing leakage or unintended agitation during maintenance process.

[0038] The extendible conduit 110 comprises flexible, chemically resistant layers supported by a guided extension means. Upon activation, the conduit 110 smoothly elongates to reach the battery ports while maintaining an airtight flow path. The conduit’s structure prevents kinking or collapse during operation, ensuring uninterrupted transfer of extracted materials between the battery and the suction unit 107, under controlled pressure conditions.

[0039] The waste chamber 108 is a sealed, corrosion-resistant containment vessel configured to safely collect extracted lithium and electrolyte materials. The waste chamber 108 is structurally reinforced to withstand chemical exposure and pressure variations during suction. The chamber 108 prevents leakage and cross-contamination, enabling secure temporary storage of degraded materials until proper disposal or further processing in accordance with safety and regulatory requirements.

[0040] Further, a scissor lift assembly 109 is integrated in the frame 102 for vertical movement of the extraction arrangement for optimal reach and precise alignment with the ports of the battery. The scissor lift assembly 109 is actuated by an integrated linear actuator; limit switches are integrated on key joints of the assembly 109 to monitor extension or retraction distance. The linear actuator and limit switches, converts linear motion into precise vertical displacement. The linear actuator extends or retracts, pushing the scissor arms to raise or lower the assembly 109. Limit switches positioned at key joints detect the maximum and minimum extension points, sending signals to the processing unit to stop motion and prevent overtravel. This coordination ensures controlled, accurate, and safe vertical positioning during battery maintenance operations.

[0041] A pneumatic cylinder is mounted horizontally between lower paired crossed arms of the scissor lift assembly 109, providing the primary linear force to extend or retract the scissor lift assembly 109. The pneumatic cylinder operates by using compressed air to generate linear mechanical motion. Internally, pressurized air is directed into a sealed chamber, causing a piston to move along the cylinder axis. This piston movement produces a controlled pushing or pulling force. By regulating air flow and pressure, smooth extension and retraction are achieved, enabling precise and repeatable actuation within the assembly 109.

[0042] A replenishment arrangement is provided to store and replenish materials for adaptive battery maintenance during lithium and electrolyte replenishment. The replenishment arrangement includes a first chamber 111 and a second sealed chamber 112, each chamber 111, 112 attached with a respective flexible conduit 114 integrated with a solenoid valve 115. The first chamber 111 stores fresh lithium compounds and the second chamber 112 stores high-purity electrolytes.

[0043] The flexible conduits 114 from the first and second chambers 111, 112 provide a chemically resistant and bendable path for lithium and electrolyte materials. Their construction allows smooth extension and retraction into the battery ports without kinking or leakage. The conduit 114 maintains an airtight flow path, ensuring precise and controlled delivery of materials from the respective chambers 111, 112 during the replenishment process.

[0044] The solenoid valve controls the flow of lithium and electrolyte materials by using an electromagnetic coil to actuate a movable plunger. When energized by the processing unit, the coil generates a magnetic field that lifts or shifts the plunger, opening or closing the passage. This allows precise, on-demand flow from the chambers 111, 112 into the flexible conduits 114. Deactivation of the coil returns the plunger to its original position, sealing the chambers 111, 112 and preventing backflow or leakage.

[0045] A six-bar linkage assembly 113 is integrated with the frame 102 to enable horizontal translation of the replenishment arrangement during battery. The six-bar linkage assembly 113 converts input motion into controlled horizontal translation of the replenishment module. Its arrangement of interconnected links and pivot joints allows coordinated movement while maintaining orientation and stability. When actuated by the processing unit, the input force propagates through the linkage, producing smooth linear motion of the replenishment arrangement toward the battery. The geometric configuration ensures precise alignment of the conduit 114 with battery ports, enabling accurate material replenishment while minimizing lateral displacement or misalignment during operation.

[0046] A blockchain-secured cloud-based data is interlinked with the platform 101 to log battery health metrics, and replenishment events for traceability. The logs include real-time sensor data, including battery state of charge, degradation levels, replenishment volumes, and extracted amounts of materials. The blockchain-secured cloud-based data records battery health metrics and replenishment events in an immutable ledger. Internally, each data entry is encrypted and linked to previous entries, ensuring tamper-proof traceability. When activated by the processing unit, sensor readings and maintenance actions are validated and securely uploaded to the cloud, allowing real-time monitoring, auditability, and transparent tracking of all battery maintenance activities.

[0047] Additionally, a user interface installable on a computing unit to enable remote monitoring of battery maintenance. The interface enables EV operators to schedule battery maintenance schedules without disturbing the vehicle operations. The user interface operates as the interactive medium for remote monitoring and control. Internally, the user interface processes input commands from the user, such as scheduling maintenance or viewing battery status, and communicates these instructions to the processing unit. The user interface receives real-time data, including battery health metrics and replenishment logs, and translates them into graphical or textual displays. The interface ensures intuitive interaction, synchronizes with the cloud for updated information, and provides actionable feedback to the user without disrupting ongoing maintenance operations.

[0048] The computing unit functions as the hardware platform 101 supporting the user interface and system communication. Internally, the computing unit executes software instructions to handle data processing, network connectivity, and interface rendering. The computing unit manages the transmission of commands from the interface to the processing unit and receives status updates, sensor readings, and logs. The computing unit coordinates with cloud services for secure data storage, enabling real-time monitoring, scheduling, and reporting while maintaining reliable operation and seamless integration with the system.

[0049] The present invention works best in the following manner, where the EV battery as disclosed in the invention is first positioned securely on the rectangular platform 101, providing the stable base for maintenance operations. The processing unit activates the motorized guiding rail frame 102, causing the interconnected telescopic segments to extend and align precisely around the battery. The electromagnetic clamps 103 mounted on the telescopic arms 104 engage the battery, and the integrated force sensors ensure secure retention by adjusting clamping force as needed. The articulated arm 106 positions the embedded sensors to monitor battery health, detecting lithium and electrolyte levels, temperature, and overall electrochemical condition. Upon determination of degradation or imbalance, the processing unit actuates the extraction arrangement, extending the conduit 110 into the battery ports and activating the suction unit 107 to remove degraded materials into the waste chamber 108. Following extraction, the processing unit coordinates the replenishment arrangement, extending flexible conduits 114 from the first and second chambers 111, 112 into the battery ports. The solenoid valves 115 control precise release of fresh lithium compounds and high-purity electrolytes.

[0050] In continuation, the six-bar linkage assembly 113 translates the replenishment arrangement horizontally for accurate alignment, while the scissor lift assembly 109 raises or lowers the extraction and replenishment modules vertically as required. The limit switches on key joints prevent overtravel and maintain precise vertical positioning, and the pneumatic cylinder provides primary linear force to the scissor lift assembly 109. Throughout the process, the blockchain-secured cloud-based data logs real-time sensor data, including battery state-of-charge, material extraction volumes, and replenishment events, ensuring traceable and secure records. Simultaneously, the user interface on the computing unit enables operators to monitor progress remotely, schedule maintenance events, and access system feedback without interrupting vehicle operations.

[0051] 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 electric vehicle battery maintenance and optimization system, comprising:
a) a rectangular platform 101 configured as an EV (electric vehicle) battery holding base;
b) a motorized guiding rail frame 102 integrated around outer periphery of the rectangular platform 101, the frame 102 fabricated of interconnected telescopic segments with integrated linear actuators;
c) a plurality of electromagnetic clamps 103 mounted at a proximal end of telescopic arms 104, the arms 104 integrated around base periphery of the rectangular frame 102, to hold EV battery;
d) a plurality of sensors 105 embedded at a proximal tip of an articulated arm 106, configured to detect lithium and electrolytes levels in the battery;
e) an extraction arrangement configured to extract degraded lithium and electrolytes from the battery, the arrangement includes a suction unit 107 integrated in a waste chamber 108, and an extendible conduit 110 attached to the chamber 108;
f) a replenishment arrangement provided to store and replenish materials for adaptive battery maintenance during lithium and electrolyte replenishment, the arrangement includes a first and a second sealed chamber 111, 112, each chamber 111, 112 attached with a respective flexible conduit 114 integrated with a solenoid valve 115;
g) a scissor lift assembly 109 is integrated in the frame 102, for vertical movement of the extraction arrangement for optimal reach and precise alignment with the ports of the battery;
h) a six-bar linkage assembly 113 integrated with the frame 102, to enable horizontal translation of the replenishment module during battery replenishment;
i) a blockchain-secured cloud-based data associated with the system to log battery health metrics, and replenishment events for traceability;
j) a user interface installable on a computing unit to enable remote monitoring of battery maintenance; and
k) a processing unit;
wherein the processing unit is operatively coupled to the mechanical and electronic components of the system.

2) The system as claimed in claim 1, wherein a plurality of LiDAR (Light Detection and Ranging) sensors is integrated in the frame 102, configured to determine a battery’s dimensions upon accurate detection of battery’s dimensions, the processing unit triggers the extension, contraction, and locking of the telescopic segments to securely align the frame 102 with the base of the battery.

3) The system as claimed in claim 1, wherein a force sensor is integrated into each clamp 103 and upon detection of a deviation in force indicating loosening, the magnetic field of the respective clamp 103 is increased to restore clamping.

4) The system as claimed in claim 1, wherein the plurality of sensors 105 include an electrochemical impedance spectroscopy (EIS) sensor, a lithium ion concentration sensor, an electrolyte composition analyzer for monitoring pH, conductivity, and decomposition products, and a temperature sensor.

5) The system as claimed in claim 1, wherein upon determination of degradation levels of lithium and electrolytes in the battery by the sensors 105, the conduit 110 extends into the battery ports and the suction unit 107 is activated to suck out the ingredients from the battery into the waste chamber 108.

6) The system as claimed in claim 1, wherein the first chamber 111 stores fresh lithium compounds and the second chamber 112 stores high-purity electrolytes, post extraction, the corresponding conduit 110 extend into the battery ports to replenish materials from the respective chambers 111, 112.

7) The system as claimed in claim 1, wherein a pneumatic cylinder is mounted horizontally between lower paired crossed arms of the scissor lift assembly 109, providing the primary linear force to extend or retract the scissor lift assembly 109.

8) The system as claimed in claim 1, wherein the assembly 113 is actuated by an integrated linear actuator, limit switches are integrated on key joints of the assembly 113 to monitor extension or retraction distance.

9) The system as claimed in claim 1, wherein the logs include real-time sensor data, including battery state of charge, degradation levels, replenishment volumes, and extracted amounts of materials.

10) The system as claimed in claim 1, wherein the interface enables EV operators to schedule battery maintenance schedules without disturbing the vehicle operations.