Description:TECHNICAL FIELD
The present disclosure relates generally to the field of electric vehicles (EVs) and battery servicing systems, and more specifically to an electric vehicle (EV) battery system, an electric vehicle (EV), and a method of battery swapping using the EV battery system.
BACKGROUND
The automotive industry is gradually shifting towards electric vehicles (EVs) to cut down on carbon emissions and decrease dependence on fossil fuels. However, EV batteries need regular charging for long trips. The limited travel range of EVs and the long time needed to recharge their batteries are major challenges in the global adoption of electric vehicles. Furthermore, range anxiety, the fear of running out of battery power before reaching a destination or charging station, is a major concern for potential four-wheeler EV buyers and acts as a barrier to the widespread adoption of four-wheeler EVs.
Four-wheeler EVs usually rely on fixed battery systems that are recharged with plug-in electric chargers. However, recharging these batteries takes a long time. Currently, battery swapping systems have been introduced, which involve exchanging discharged batteries for fully charged ones at dedicated swapping stations. However, current battery swapping systems often encounter problems such as incompatibility of batteries with various vehicle models, complex mechanical processes, and the need for extensive infrastructure, which not only results in prolonged battery swap times but also higher costs of battery swapping. Thus, there exists a technical problem of how to provide a simple, economical, but technically advanced system that can solve the technical problem of long EV charging time without increasing the complexity and cost of EV charging infrastructure. Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional EV battery systems, conventional EVs, and the conventional methods of battery swapping.
SUMMARY
The present disclosure provides an electric vehicle (EV) battery system, an EV, and a method of battery swapping using the EV battery system. The present disclosure provides a solution to the existing problem of how to provide a simple, economical, but technically advanced system or electric vehicle which can solve the issue of long EV charging time without increasing the complexity and cost of EV charging infrastructure. An objective of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provides an improved electric vehicle (EV) battery system, an improved EV, and an improved method of battery swapping using the EV battery system.
One or more objectives of the present disclosure are achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
In one aspect, the present disclosure provides an EV battery system that includes a fixed battery installed in a first section of a chassis of a four-wheeler EV underbody. Further, the EV battery system includes an add-on battery slot configured to hold a removable add-on battery in a second section of the chassis of the four-wheeler electric vehicle underbody. Furthermore, the EV battery system includes a rapid-connect coolant connector set configured to establish a detachable connection with the removable add-on battery to maintain an operating temperature of the removable add-on battery in a specified range during a ride of a four-wheeler EV. The EV battery system includes a rapid-connect High-Voltage and Low-Voltage (HV-LV) connector set configured to establish a detachable electrical connection with the removable add-on battery and a vehicle control unit (VCU). Moreover, the VCU is configured to detect the presence of the removable add-on battery when the removable add-on battery is installed in the add-on battery slot of the four-wheeler EV underbody. Additionally, the VCU is further configured to automatically switch from the fixed battery to the removable add-on battery to power the four-wheeler EV during the ride exclusively from the removable add-on battery.
The EV battery system provides a simple and economical solution to the long EV charging time without increasing the complexity and cost of EV charging infrastructure. The EV battery system solves the long-standing problem specific to the EV industry of the range anxiety or the fear of running out of battery power before reaching a given destination. The EV battery system provides an electric vehicle with two types of batteries (i.e., one fixed battery and the other removable add-on battery as swappable) to extend the driving range of the four-wheeler EV vehicle. Furthermore, beneficially, the electric vehicle battery system provides flexibility in the usage of the removable add-on battery. For instance, the EV battery system reduces the initial cost of the four-wheeler EV to the consumer (as compared to conventional EV systems) by providing a battery size of optimized capacity in the form of the fixed battery, which can cover the daily travel needs and further provides the removable add-on battery for long distance discretionary travel on a swappable basis using, for example, “Battery as a Service”. In other words, for example, a user can use only the fixed battery for short trips in order to reduce the dead weight of any additional battery and can utilize the removable add-on battery along with the fixed battery for long trips. Furthermore, the electric vehicle battery system includes various components, which are specially designed and developed to reduce the overall vehicle mass and thereby optimize the drivetrain capacity and the battery consumption by avoiding the installation of a single heavy battery (like in conventional EVs) for a similar range instead of two optimized batteries used in the present invention to reduce the dead weight un-necessarily required to be carried for the daily commute.
Further, the rapid-connect HV-LV connector set enables a quick fixing and detachment of the removable add-on battery with the chassis of the four-wheeler vehicle, thereby reducing the downtime as compared to the traditional battery swapping systems. Additionally, the rapid-connect coolant connector set ensures optimum operating temperature for the removable add-on battery during its operation. In the present invention, advantageously, the VCU automatically switches from the fixed battery to the removable add-on battery to power the four-wheeler EV during the ride exclusively from the removable add-on battery. This significantly contributes to extending the range of the four-wheeler vehicle by swapping it rapidly (almost similar time as filling fuel) making it convenient for consumers as compared to current battery charging solutions, like direct current (DC) quick charging of 30-50 minutes time currently required. This charging time currently also adds up due to the queue in charging stations for each EV charging cycle time.
In another aspect, the present disclosure provides a four-wheeler EV that includes a fixed battery installed in a first section of the chassis of the four-wheeler EV. The four-wheeler EV further includes an add-on battery slot configured to hold a removable add-on battery in a second section of the chassis of the four-wheeler electric vehicle underbody. Furthermore, the four-wheeler EV includes a rapid-connect coolant connector set configured to establish a detachable connection with the removable add-on battery to maintain an operating temperature of the removable add-on battery in a specified range during a ride of a four-wheeler EV. Moreover, the four-wheeler EV includes a rapid-connect High-Voltage and Low-Voltage (HV-LV) connector set configured to establish a detachable electrical connection with the removable add-on battery and a vehicle control unit (VCU) configured to detect the presence of the removable add-on battery when the removable add-on battery is installed in the add-on battery slot of the four-wheeler EV underbody. Moreover, the VCU is further configured to automatically switch from the fixed battery to the removable add-on battery to power the four-wheeler EV during the ride exclusively from the removable add-on battery. The four-wheeler EV achieves all the advantages and technical effects of the electric vehicle battery system.
In another aspect, the present disclosure provides a method of battery swapping using an EV battery system. The method includes establishing a detachable connection with the removable add-on battery of the four-wheeler EV using the rapid-connect coolant connector set of the electric vehicle battery system to maintain an operating temperature of the removable add-on battery in a specified range during a ride of the four-wheeler EV. Further, the method includes establishing a detachable electrical connection with the removable add-on battery using the rapid-connect HV-LV connector set of the EV battery system. Furthermore, the method includes detecting the presence of the removable add-on battery when the removable add-on battery is installed in the add-on battery slot of the four-wheeler EV underbody by the VCU of the four-wheeler EV. Moreover, the method includes automatically switching from the fixed battery to the removable add-on battery to power the four-wheeler EV during the ride exclusively from the removable add-on battery by the VCU.
The disclosed method of battery swapping using an EV battery system achieves all the advantages and technical effects of the EV battery system.
It is to be appreciated that all the aforementioned implementation forms can be combined. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a block diagram that depicts an electric vehicle (EV) battery system, in accordance with an embodiment of the present disclosure;
FIG. 2 is a diagram illustrating a chassis portion of an EV, in accordance with an embodiment of the present disclosure;
FIG. 3 is a diagram illustrating a chassis structural member of a four-wheeler EV, in accordance with an embodiment of the present disclosure;
FIG. 4 is a diagram illustrating an assembly of a chassis structural member with a fixed battery and a removable add-on battery, in accordance with an embodiment of the present disclosure;
FIG. 5 is a diagram illustrating a robotic trolley assembly with a scissor lift used in a swapping station, in accordance with an embodiment of the present disclosure;
FIG. 6 is a diagram illustrating a four-wheeler EV positioned at a defined spot at a battery swapping station for automatic installation or removal of removable add-on battery in different scenarios using a robotic trolley assembly, in accordance with an embodiment of the present disclosure; and
FIG. 7 is a flow chart that illustrates a method of battery swapping using an EV battery system, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
FIG. 1 is a block diagram that depicts an electric vehicle (EV) battery system, in accordance with an embodiment of the present disclosure. With the reference to FIG. 1, there is shown a block diagram of an EV battery system 100 that includes a four-wheeler EV 102 and a plurality of battery swapping stations 104. The four-wheeler EV 102 further includes a chassis structural member 106, a vehicle control unit (VCU) 118, a rapid-connect coolant connector set 114, a rapid-connect High-Voltage and Low-Voltage (HV-LV) connector set 116, an electronic device 120, and a communication network 126.
There is provided the EV battery system 100 that includes the fixed battery 108 installed in a first section of a chassis of the four-wheeler EV 102 underbody. The fixed battery 108 is securely installed within the underbody structure of the chassis structural member 106 of the four-wheeler EV 102 by using robust brackets and fasteners that are designed to withstand the dynamics of the four-wheeler EV 102.
Furthermore, the EV battery system 100 includes the add-on battery slot 110 configured to hold the removable add-on battery 112 in the second section of the chassis of the four-wheeler EV 102 underbody. The inclusion of an add-on battery slot 110 is to hold the removable add-on battery 112, that is used for extending the driving range and flexibility of the four-wheeler EV 102. For example, the removable add-on battery 112 is installed in the add-on battery slot 110 for long-distance trips and the removable add-on battery 112 can be further removed from the add-on battery slot 110 to remove the dead weight which the four-wheeler EV 102 may carry while traveling short distance trips.
In an implementation, the chassis has the chassis structural member 106 having a front section and a rear section. Moreover, the rear section is configured to support the add-on battery slot 110 at the rear side of the four-wheeler EV 102 and the front section is configured to support a fixed battery slot 124 for the fixed battery 108 at the front side of the four-wheeler EV 102. The rear section of the chassis structural member 106 is configured to support the add-on battery slot 110, which holds the removable add-on battery 112 at the rear of the four-wheeler EV 102 to allow an easy access, removal, or swapping of the removable add-on battery 112. Moreover, the front section of the chassis structural member 106 is configured to support the fixed battery slot 124, which securely holds the fixed battery 108 at the front of the four-wheeler EV 102 and provides a fixed power source for the four-wheeler EV 102. In another implementation, the chassis 202 has the chassis structural member 106 having a front section and a rear section, and the rear section is configured to support a fixed battery slot 124 for the fixed battery at a rear side of the four-wheeler EV 102 and the front section is configured to support the add-on battery slot 110 at a front side of the four-wheeler EV 102. As a result, the placement of the fixed battery 108 and the removable add-on battery 112 ensures a reliable weight distribution thereby enhancing the overall stability of the four-wheeler EV 102.
Furthermore, the EV battery system 100 includes the rapid-connect coolant connector set 114 configured to establish a detachable connection with the removable add-on battery 112 to maintain an operating temperature of the removable add-on battery 112 in a specified range during a ride of the four-wheeler EV 102. In an implementation, the rapid-connect coolant connector set 114 ensures that the removable add-on battery 112 remains within a specified operating temperature range during the ride of the four-wheeler EV 102 by providing a supply of coolant via cooling system, which is crucial for maintaining optimal performance and longevity of the removable add-on battery 112, as extreme temperature can lead to decreased performance and reduced lifespan of the removable add-on battery 112. Further, the rapid-connect coolant connector set 114 includes a female coolant connector mounted on the chassis structural member 106 and a male coolant connector mounted on the removable add-on battery 112, designed to automatically engage when the removable add-on battery 112 is installed and disengage when the removable add-on battery 112 is removed.
Furthermore, the EV battery system 100 includes a rapid-connect HV-LV connector set 116 configured to establish the detachable electrical connection with the removable add-on battery 112. The rapid-connect HV-LV connector set 116 consists of a female HV-LV connector mounted on the chassis structural member 106 and a male HV-LV connector mounted on the removable add-on battery 112. Furthermore, the male and female HV-LV connector automatically engage, establishing a secure and reliable electrical connection, when the removable add-on battery 112 is installed in the add-on battery slot 110 of the four-wheeler EV 102. Similarly, the male and female HV-LV connector automatically disengages, when the removable add-on battery 112 is removed from the add-on battery slot 110 of the four-wheeler EV 102. Thus, the ability of the rapid-connect HV-LV connector set 116 to quickly connect and disconnect the removable add-on battery simplifies the battery-swapping process, making the battery-swapping process more user-friendly and time-efficient.
Furthermore, the EV battery system 100 includes the VCU 118 configured to detect the presence of the removable add-on battery 112, when the removable add-on battery 112 is installed in the add-on battery slot 110 of the four-wheeler EV 102 underbody. In an implementation, VCU 118 is configured to utilize the electrical connections to detect when the removable add-on battery 112 is installed in the add-on battery slot 110 of the four-wheeler EV. Furthermore, once the removable add-on battery 112 is detected, the VCU 118 initiates the processes to integrate the removable add-on battery 112 into the electrical system of the four-wheeler EV and shifts the power supply of the electric motor of the four-wheeler EV 102 towards the removable add-on battery 112. In an implementation, the VCU 118 can monitor the health and status of the removable add-on battery 112, providing diagnostic information that can help in maintaining the battery performance of the four-wheeler EV 102. In an implementation, the VCU 118 is configured to automatically switch from the fixed battery 108 to the removable add-on battery 112 to power the four-wheeler EV 102 during the ride exclusively from the removable add-on battery 112, thereby reducing the need for frequent charging or battery swapping stops, thereby ensuring a continuous and reliable vehicle operation, and enhancing the user experience.
In accordance with an embodiment, the rapid-connect coolant connector set 114 comprises a female coolant connector mounted on the chassis structural member 106 and a male coolant connector mounted on the removable add-on battery 112. Furthermore, the female coolant connector is configured to automatically engage and disengage with the male coolant connector during installation and removal of the removable add-on battery, respectively. The automatic engagement and disengagement of the rapid-connect coolant connector set 114 is crucial for maintaining the operating temperature of the removable add-on battery 112, as effective temperature management is essential for the performance, safety, and longevity of the removable add-on battery 112.
In accordance with an embodiment, the rapid-connect HV-LV connector set 116 comprises a female HV-LV connector mounted on the chassis structural member 106 and a male HV-LV connector mounted on the removable add-on battery 112. Furthermore, the female HV-LV connector is configured to automatically engage and disengage with the male HV-LV connector during installation and removal of the removable add-on battery, respectively. The automatic engagement and disengagement mechanism of the rapid-connect HV-LV connector set 116 is essential for ensuring a reliable and efficient electrical connection between the various electrical systems of the four-wheeler EV 102 and the removable add-on battery 112. Additionally, the incorporation of the rapid-connect HV-LV connector set 116 simplifies the battery-swapping process, making the battery-swapping process faster and more user-friendly by eliminating the need for manual connection and disconnection of electrical cables, thereby reducing the risk of electrical faults.
In accordance with an embodiment, the EV battery system 100 includes the electronic device 120 configured to establish a communication with the four-wheeler EV 102 via the user interface 122. The electronic device 120 utilizes wireless or wired communication technologies to connect with the four-wheeler EV 102. Examples of the electronic device 120 may include but are not limited to a smartphone, a tablet, a computing device, a vehicle-infotainment device, and the like. In an implementation, the electronic device 120 is used by a user 128. Moreover, by using the user interface 122, the electronic device 120 can send and receive data, commands, and notifications. In an example, the user 128 is configured to check the battery level, locate nearby battery swapping station, and initiate battery swapping procedures using the electronic device 120.
In accordance with an embodiment, the electronic device 120 is further configured to establish communication with the nearby battery swapping station to reserve an upcoming time slot to perform at least one function of an install function for the installation of a new removable add-on battery that is pre-charged at the nearby battery swapping station when the add-on battery slot 110 is vacant, a remove and return function for removal and return of the removable add-on battery 112 with a depleted charge state at the nearby battery swapping station if already installed in the four-wheeler EV 102, or a swap function for swapping of the removable add-on battery 112 with a depleted charge state installed in the four-wheeler EV 102 with a new removable add-on battery that is pre-charged at the nearby battery swapping station. By allowing users to reserve time slots for battery-related functions, the EV battery system 100 is configured to reduce the wait time and ensures that pre-charged removable add-on batteries are available when needed. In an implementation, the electronic device 120 communicates with the nearby battery swapping station using wireless communication protocols, such as cellular networks, Wi-Fi, Bluetooth, and the like.
Moreover, once a reservation is made, the electronic device 120 is configured to send a confirmation to the nearby battery swapping station, which then prepares for the scheduled operation. Additionally, upon arrival of the four-wheeler EV 102 at the nearby swapping station, the electronic device 120 verifies the reservation and coordinates the execution of the selected function, ensuring a smooth and automated process, thereby significantly reducing downtime by ensuring that battery swapping operations are pre-scheduled and ready upon the arrival of the four-wheeler EV 102.
In accordance with an embodiment, the electronic device 120 is further configured to communicate with the nearby battery swapping station to instruct which function of the install function, the remove and return function or the swap function is to be performed at the nearby battery swapping station when the four-wheeler EV 102 reaches the nearby battery swapping station. In an implementation, the communication between the electronic device 120 and the nearby swapping station includes sending instructions on specific steps to be taken like installing a new removable add-on battery, removing and returning a depleted add-on battery, or swapping a depleted add-on battery with a pre-charged one, when the four-wheeler EV 102 arrives at the nearby swapping station. The electronic device 120 communicates with the nearby battery swapping station through wireless communication technologies such as cellular networks, Wi-Fi, or Bluetooth. Furthermore, when the four-wheeler EV 102 reaches a nearby battery swapping station, the electronic device 120 sends a predefined set of instructions indicating the required operation (install, remove and return, or swap) based on the current status and needs of the four-wheeler EV, which are determined by the electronic device 120 in conjunction with the VCU 118. Thus, the ability of the electronic device 120 to pre-instruct the nearby battery swapping station significantly reduces the waiting time for the user 128 (or driver), as the nearby swapping station can immediately begin the required operation without the need for further input or diagnostics of the four-wheeler EV 102.
In accordance with an embodiment, the electronic device 120 is further configured to initiate and control a transaction event with the nearby battery swapping station when one of the install function, the remove and return function, or the swap function is completed at the nearby battery swapping station, based on the established communication with the nearby battery swapping station and the four-wheeler EV 102. The electronic device 120 is further configured to initiate and control a transaction event with the nearby battery swapping station based on the communication established with the nearby battery swapping station and the four-wheeler EV 102. In an implementation, once the selected battery operation (i.e., install, remove and return, or swap) is completed at the nearby swapping station, the electronic device 120 is configured to automatically initiate the transaction process, calculate the charges on the service provided, and then processes the payment through pre-stored user payment information, such as credit card details or a digital wallet. Additionally, the electronic device 120 is further configured to provide an immediate receipt to the user 128 (or driver), thereby confirming the successful completion of the service. In another implementation, the electronic device can also offer battery swapping on a subscription basis providing a predictable and consistent cost structure for the user 128 (or driver), which enhances user convenience and affordability. Moreover, the secure handling of payment information and immediate processing of transactions also increase user trust and satisfaction.
Advantageously, the EV battery system 100 has a fixed battery 108 installed in the front section of the chassis of the four-wheeler EV 102, which optimizes the weight distribution between the front and rear axles of the four-wheeler EV 102, enhancing the stability, handling, and safety of the four-wheeler EV 102. Furthermore, the EV battery system 100 includes the add-on battery slot 110 in the rear section of the chassis of the four-wheeler EV 102 for a removable add-on battery 112, extending the driving range of the four-wheeler EV and providing flexibility to the users to use the four-wheeler EV 102 either for a long or a short distance drive according to need. Moreover, the inclusion of the rapid-connect coolant connector set 114 and rapid-connect HV-LV connector set 116 for providing coolant and electrical connections to the removable add-on battery 112 ensures the quick and secure battery swapping, thereby enhancing the operational efficiency of the EV battery system 100. Additionally, the VCU 118 detects and integrates the removable add-on battery 112 to the add-on battery slot 110, ensuring an efficient power management and seamless switching between both batteries as per the operational needs. Furthermore, the electronic device 120 facilitates user interaction and communication with nearby battery-swapping stations, enabling reservations and transaction management, which streamlines the battery-swapping process. The above features of the EV battery system collectively improve the performance and safety of the four-wheeler EV 102, also increase the convenience of the user, and reduce the operational cost of the battery swapping process.
FIG. 2 is a diagram illustrating a chassis portion of an EV, in accordance with an embodiment of the present disclosure. FIG. 2 is described in conjunction with elements from FIG. 1. With reference to FIG. 2, there is shown a diagram 200, that includes a chassis 202 of the four-wheeler EV 102. The chassis 202 further includes the chassis structural member 106.
The chassis 202 refers to a structural framework of the four-wheeler EV 102, which supports the body of the four-wheeler EV 102, and the various components of the four-wheeler EV 102, such as the fixed battery 108, the removable add-on battery 112, and other essential components of the four-wheeler EV 102. Furthermore, the chassis 200 has the chassis structural member 106 having a front section and a rear section. In an example, the rear section of the chassis structural member 106 is configured to support the add-on battery slot 110 at the rear side of the four-wheeler EV 102 and the front section is configured to support a fixed battery slot 124 for the fixed battery 108 at a front side of the four-wheeler EV 102. Moreover, by placing the fixed battery slot 124 at the front and the add-on battery slot 110 at the rear, the weight of the four-wheeler EV 102 gets balanced evenly across the axles of the four-wheeler EV 102. Further, the balanced distribution of the weight is crucial for enhancing the stability and handling of the four-wheeler EV 102. In another example, the rear section of the chassis structural member 106 is configured to support a fixed battery slot 124 for the fixed battery at the rear side of the four-wheeler EV 102 and the front section is configured to support the add-on battery slot 110 at a front side of the four-wheeler EV 102. As a result, the placement of the fixed battery 108 and the removable add-on battery 112 ensures a reliable weight distribution thereby enhancing the overall stability of the four-wheeler EV 102.
In accordance with an embodiment, the chassis 202 of the four-wheeler EV 102 underbody comprises a flexible multi-battery packaging configuration to accommodate and support installation of the fixed battery and the removable add-on battery independent of a battery size, a battery chemistry, or a battery capacity of the fixed battery or the removable add-on battery. The chassis 202 achieves the flexibility of a multi-battery packaging configuration through a design that includes adjustable and adaptable mounting mechanisms for the batteries, that securely hold the batteries of different sizes and shapes. The design further incorporates electrical and thermal management systems that can manage various battery chemistries and capacities, thereby ensuring that the batteries operate efficiently and safely, regardless of their specific characteristics. Furthermore, the design of the chassis 202 ensures easy installation and removal of batteries, which simplifies the maintenance and battery swapping, reducing downtime and operational cost of battery swapping.
Advantageously, the flexibility in placing the fixed battery slot 124 and the add-on battery slot 110 at the front and the rear end of the chassis structural member 106 of the four-wheeler EV 102, ensures that the weight of the batteries is evenly distributed along the length of the four-wheeler EV 102, preventing any imbalance that could affect handling or safety of the four-wheeler EV 102. Furthermore, the design of the chassis 202 significantly contributes to the long-term reliability and performance of the four-wheeler EV 102 by combining structural strength with strategic weight management of the four-wheeler EV 102.
FIG. 3 is a diagram illustrating a chassis structural member of a four-wheeler EV, in accordance with an embodiment of the present disclosure. FIG. 3 is described in conjunction with elements from FIG. 1. With reference to FIG. 3, there is shown a diagram 300, that includes the chassis structural member 106. The chassis structural member 106 further includes the fixed battery slot 124 and the add-on battery slot 110.
The chassis structural member 106 serves as the structural framework designed to support both the fixed battery 108 and the removable add-on battery 112. Further, the fixed battery slot 124 is positioned to securely hold the fixed battery 108, ensuring the stability of the fixed battery 108 during the operation of the four-wheeler EV 102. Similarly, the add-on battery slot 110 is configured to hold the removable add-on battery 112, providing a robust and stable placement for the removable add-on battery 112. Furthermore, the positioning of the fixed battery slot 124 and the add-on battery slot 110 within the chassis structural member 106 helps the chassis structural member 106 to achieve an optimal weight distribution between the front and rear sections. Moreover, the secure and stable placement of the fixed battery 108 and the removable add-on battery 112 reduces the risk of battery movement or detachment during the operation of the four-wheeler EV 102, thereby minimizing the risk of accidents or damage. Additionally, the chassis structural member 106 of the four-wheeler EV 102 further includes strong brackets and fasteners, which ensures that both the batteries i.e., the fixed battery 108 and the removable add-on battery 112 remain firmly in place, enhancing the durability and reliability of the four-wheeler EV 102 over time.
Advantageously, by ensuring the fixed battery slot 124 securely holds the fixed battery 108, and the add-on battery slot 110 provides a robust placement for the removable add-on battery 112, the chassis structural member 106 significantly enhances the stability of the batteries during the operation of the four-wheeler EV 102. Furthermore, the positioning of the fixed battery slot 124 and the add-on battery slot 110 within the chassis structural member 106 ensures an optimal weight distribution between the front and rear sections of the four-wheeler EV 102. Moreover, the inclusion of strong brackets and fasteners within the chassis structural member 106 reinforces the secure placement of both the fixed battery 108 and the removable add-on battery 112.
FIG. 4 is a diagram illustrating an assembly of a chassis structural member with a fixed battery and a removable add-on battery, in accordance with an embodiment of the present disclosure. FIG. 4 is described in conjunction with elements from FIG. 1. With reference to FIG. 4, there is shown a diagram 400, that includes the chassis structural member 106. The chassis structural member further includes the fixed battery slot 124 for the fixed battery 108 and the add-on battery slot 110 for the removable add-on battery 112. Furthermore, the chassis structural member 106 includes a female coolant connector 402 and a female HV-LV connector 406. The removable add-on battery 112 includes the male coolant connector installed on the removable add-on battery 112.
The female coolant connector 402 is installed on the chassis structural member 106 to facilitate coolant fluid transfer between the cooling system of the four-wheeler EV 102 and the removable add-on battery 112. The female coolant connector 402 connector ensures a secure, leak-proof interface with the corresponding male coolant connector 404 on the removable add-on battery 112, enabling effective thermal regulation that prevents battery overheating. The female HV-LV connector 406 is mounted on the chassis structural member 106 to facilitate the connection between the electrical system of the four-wheeler EV 102 and the removable add-on battery 112. The female HV-LV connector 406 interfaces securely with the male HV-LV connector 408 on the removable add-on battery 112, enabling the safe and efficient transfer of high-voltage (HV) and low-voltage (LV) electrical power.
Furthermore, the integration of the male and female coolant connector as well as male and female HV-LV connectors ensures both the fixed battery 108 and the removable add-on battery 112 are securely and efficiently connected to the EV battery system 100. Moreover, the integration of the male and female coolant connectors as well as the male and female HV-LV connectors enhances the modularity and flexibility of the EV battery system 100 by allowing for seamless integration of different types of batteries, facilitating upgrades or replacements of the removable add-on battery without extensive modifications to the EV battery system 100.
Advantageously, the inclusion of the male and female coolant connectors ensures that both batteries i.e., the fixed battery 108 and the removable add-on battery 112 can be effectively cooled, preventing any overheating, and ensuring optimal performance and longevity of the fixed battery 108 and the removable add-on battery 112. Additionally, the HV-LV connectors provide an efficient electrical connection, ensuring that the four-wheeler EV effectively manages and utilizes the power from both batteries i.e., the fixed battery 108 and the removable add-on battery 112, thereby enhancing the overall performance and range of the four-wheeler EV 102.
FIG. 5 is a diagram illustrating a robotic trolley assembly with a scissor lift used in a swapping station, in accordance with an embodiment of the present disclosure. With reference to FIG. 5, there is shown a diagram 500, that includes a robotic trolley assembly 502, that includes a trolley 504, a scissor lift 506, a platform 508, a plurality of sensors 510, and battery mounting bolt tightening device 512.
In an implementation, the battery swapping process begins with the four-wheeler EV 102 arriving at the battery swapping station and being properly aligned on an elevated ramp to position the four-wheeler EV above the robotic trolley assembly 502. The robotic trolley assembly 502, which includes the trolley 504, the scissor lift 506, the platform 508, and the plurality of sensors 510, is then prepared to facilitate the battery swapping process.
In an example, when the four-wheeler EV 102 has the fixed battery 108 installed but the add-on battery slot 110 is vacant, the scissor lift 506 is configured to place a charged removable add-on battery 112 into the add-on battery slot 110. At first, the plurality of sensors 510 on the robotic trolley assembly 502 detects and confirms the exact position and alignment of the add-on battery slot 110 that is vaccated. Then, the platform 508, which holds the charged removable add-on battery, is raised by the scissor lift 506. Once the platform 508 reaches an appropriate height, where the charged removable add-on battery is aligned with the add-on battery slot 110, the scissor lift mechanism gently places the charged removable add-on battery into the add-on battery slot 110. The battery mounting bolt tightening device 512 then engages to secure the battery in the slot, ensuring that the mounting bolts are tightened to the appropriate torque specifications.
In another example, when the four-wheeler EV 102 has a fixed battery 108 and a discharged removable add-on battery 112 installed, the scissor lift is configured to install a charged removable add-on battery in place of the discharged removable add-on battery 112 in the add-on battery slot 110. Initially, the plurality of sensors 510 on the robotic trolley assembly 502 detects and confirms the exact position and alignment of the add-on battery slot 110 containing the discharged removable add-on battery 112. The scissor lift mechanism then raises the platform 508, which holds the replacement charged removable add-on battery, using the scissor lift 506. Once the platform 508 reaches an appropriate height and is aligned with the add-on battery slot 110, the scissor lift mechanism first removes the discharged removable add-on battery 112 by loosening the mounting bolts of the discharged removable add-on battery 112 by the battery mounting bolt tightening device 512. The robotic trolley assembly 502, then places the charged removable add-on battery into the add-on battery slot 110. The battery mounting bolt tightening device 512 then engages to secure the new battery in the add-on battery slot, thereby completing the battery swap.
Advantageously, the scissor lift 506 is designed in a crisscross pattern, connected at pivot points, allowing for smooth expansion and contraction, thereby ensuring that the movement of the robotic trolley assembly 502 is stable and controlled, preventing sudden jolts or misalignment during the battery exchange process. Furthermore, the platform 508 is designed to remain stable and level during the movement of the scissor lift 506, providing a secure surface for the removable add-on battery 112 to be installed into the add-on battery slot 110. Once the platform reaches the appropriate height, the battery mounting bolt tightening device 512 secures the battery mounting bolts to the correct torque specifications, thereby ensuring that the removable add-on battery 112 is firmly held in place, preventing any movement or disconnection during the operation of the four-wheeler EV 102. Additionally, the scissor lift is configured to minimize downtime, optimize battery utilization, and enhance the overall efficiency and reliability of the EV battery swapping.
FIG. 6 is a diagram illustrating a four-wheeler EV positioned at a defined spot at a battery swapping station for automatic installation or removal of removable add-on battery in different scenarios using a robotic trolley assembly, in accordance with an embodiment of the present disclosure. FIG. 6 is described in conjunction with elements from FIGs. 1 to 5. With reference to FIG. 6, there is shown a diagram 600 of the battery swapping station, that includes a first trolley 602A, a second trolley 602B, a first rack 604A for charged removable add-on batteries, a second rack 604B for discharged removable add-on batteries, the four-wheeler EV 102, a ramp 606, a vehicle stopper 608, a tyre guiding channel 610, and a guide rails 612.
In an implementation, the user 128 rides the four-wheeler EV 102 over the ramp 606 and park the four-wheeler EV 102 by touching the front of the vehicle stopper 608 through the tyre guiding channel 610. The ramp 606 refers to an elevated platform that includes tyre guiding channel 610 to ensure that the four-wheeler EV 102 is positioned properly for the battery swapping operation. In an implementation, the vehicle stopper 608 is further configured to assist in aligning the four-wheeler EV 102 to facilitate the smooth operation of the first trolley 602A and the second trolley 602B during the battery swapping process. Thereafter, the battery assembly operation is initiated after locking the wheels of the four-wheeler EV 102 on the ramp 606. The first trolley 602A is used to transport the charged batteries within the battery swapping station from the first rack 604A to the robotic trolley assembly 502, and the second trolley 602B is used to transport the discharged batteries within the battery swapping station from the robotic trolley assembly 502 to the second rack 604B. Moreover, the first trolley 602A and the second trolley 602B are configured to move along the guide rails 612 (or rails and wheels), facilitating the smooth movement of the first trolley 602A and the second trolley 602B within the battery swapping station. When the four-wheeler EV 102 is positioned on a pre-defined spot on the ramp 606 of the battery swapping station, the robotic trolley assembly 502 is configured to automatically perform one of the install functions, the remove and return function, or the swap function based on the instruction received from the electronic device 120. In an example, for the install function, the first trolley 602A retrieves a charged removable add-on battery from the rack and positions the charged removable add-on battery under the four-wheeler EV 102 underbody for installation. In such an example, the first trolley 602A is configured to lift the platform (e.g., the platform 508 of FIG.5) through the scissor lift (e.g., the scissor lift 506 of FIG. 5) and raises a first battery from the first rack 604A towards the four-wheeler EV 102. After that, the first trolley 602A moves out and positions itself under the ramp 606 by using the guide rails 612. The first battery aligns with its mounting holes provided in the body of the four-wheeler EV 102. Thereafter, such mounting bolts are engaged, tightened, and torqued with the required torque. Finally, the scissor lift is lowered down and the first trolley 602A is returned back to its parking spot the four-wheeler EV 102 receives a display and sound notification indicating that the battery assembly operation is completed to allow the user to remove the four-wheeler EV 102 from the ramp 606.
In another example, the second trolley 602B is configured to move out and come under the ramp 606, such as by using the guide rails 612. The scissor lift of the second trolley 602B lifts the platform towards the four-wheeler EV 102 and a nut runner gets aligned with the mounting holes of the four-wheeler EV 102. Thereafter, the battery mounting bolts are de-torqued and removed. After that, the scissor lift is lowered down and the second trolley 602B places the discharged battery in the available slot of the second rack 604B. Finally, the user of the four-wheeler EV 102 received a display and sound notification to further remove the four-wheeler EV 102 from the ramp 606. Therefore, by reducing the need for human intervention the potential for errors is reduced and a consistent, reliable battery-swapping operation can be achieved. Additionally, the precise alignment and placement capabilities of both trolleys, guided by sensors, ensure that the removable add-on batteries are securely installed or removed thereby enhancing the overall safety and reliability of the battery-swapping operation of the four-wheeler EV 102.
FIG. 7 is a flow chart that illustrates a method of battery swapping using an EV battery system, in accordance with an embodiment of the present disclosure. With reference to FIG. 7, there is a method 700 of battery swapping using the EV battery system 100 that includes steps 702 to 708.
There is provided a method of battery swapping using an EV battery system 100. The method 700 of battery swapping using an EV battery system 100 involves a systematic approach to efficiently replace and manage EV batteries. The method 700 is designed to streamline the process of swapping batteries, ensuring minimal downtime and maximum operational efficiency for electric vehicles. At step 702, the method 700 includes establishing the detachable connection with the removable add-on battery 112 of the four-wheeler EV 102 using the rapid-connect coolant connector set 114 of the EV battery system 100 to maintain an operating temperature of the removable add-on battery in a specified range during a ride of the four-wheeler EV 102. At step 704, the method 700 includes, establishing the detachable electrical connection with the removable add-on battery 112 using a rapid-connect HV-LV connector set 116 of the EV battery system 100. At step 706, the method 700 includes detecting the presence of the removable add-on battery 112 when the removable add-on battery 112 is installed in the add-on battery slot of the four-wheeler EV 102 underbody. At step 708, the method 700 includes automatically switching from the fixed battery 108 to the removable add-on battery 112 to power the four-wheeler EV 102 during the ride exclusively from the removable add-on battery 112.
The steps 702 to 708 are only illustrative, and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
Advantageously, the method 700 of battery swapping using an EV battery system includes automated detection of the removable add-on battery 112 and automatic switching from the fixed battery 108, ensuring continuous and efficient power supply during vehicle operation. Furthermore, the integrated approach minimizes downtime, enhances operational flexibility, and optimizes energy management, thereby improving overall performance, reliability, and user convenience in EV battery swapping.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components, or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.
, Claims:WE CLAIM:
1. An electric vehicle (EV) battery system (100), comprising:
a fixed battery (108) installed in a first section of a chassis (202) of a four-wheeler EV (102) underbody;
an add-on battery slot (110) configured to hold a removable add-on battery (112) in a second section of the chassis (202) of the four-wheeler EV (102) underbody;
a rapid-connect coolant connector set (114) configured to establish a detachable connection with the removable add-on battery (112) to maintain an operating temperature of the removable add-on battery (112) in a specified range during a ride of a four-wheeler EV (102);
a rapid-connect High-Voltage and Low-Voltage (HV-LV) connector set (116) configured to establish a detachable electrical connection with the removable add-on battery (112); and
a vehicle control unit (VCU) (118) configured to:
detect a presence of the removable add-on battery (112) when the removable add-on battery (112) is installed in the add-on battery slot (110) of the four-wheeler EV (102) underbody; and
automatically switch from the fixed battery (108) to the removable add-on battery (112) to power the four-wheeler EV (102) during the ride exclusively from the removable add-on battery (112).
2. The EV battery system (100) as claimed in claim 1, wherein the rapid-connect coolant connector set (114) comprises a female coolant connector (402) mounted on the chassis structural member (106) and a male coolant connector (404) mounted on the removable add-on battery (112), and wherein the female coolant connector (402) is configured to automatically engage and disengage with the male coolant connector (404) during installation and removal of the removable add-on battery (112), respectively.
3. The EV battery system (100) as claimed in claim 1, wherein the rapid-connect HV-LV connector set (116) comprises a female HV-LV connector (406) mounted on the chassis structural member (106) and a male HV-LV connector (408) mounted on the removable add-on battery (112), and wherein the female HV-LV connector (406) is configured to automatically engage and disengage with the male HV-LV connector (408) during installation and removal of the removable add-on battery (112), respectively.
4. The EV battery system (100) as claimed in claim 1, wherein the EV battery system (100) comprises an electronic device (120) configured to:
establish a communication with the four-wheeler EV (102) via a user interface (122);
locate a nearby battery swapping station from a current location of the four-wheeler EV (102) via the user interface (122); and
establish communication with the nearby battery swapping station to reserve an upcoming time slot to perform at least one function of:
an install function for installation of a new removable add-on battery that is pre-charged at the nearby battery swapping station when the add-on battery slot (110) is vacant,
a remove and return function for removal and return of the removable add-on battery (112) with a depleted charge state at the nearby battery swapping station if already installed in the four-wheeler EV (102), or
a swap function for swapping of the removable add-on battery (112) with a depleted charge state installed in the four-wheeler EV (102) with a new removable add-on battery that is pre-charged at the nearby battery swapping station.
5. The EV battery system (100) as claimed in claim 4, wherein the electronic device (120) is further configured to:
communicate with the nearby battery swapping station to instruct which function of the install function, the remove and return function, or the swap function is to be performed at the nearby battery swapping station when the four-wheeler EV (102) reaches the nearby battery swapping station; and
initiate and control a transaction event with the nearby battery swapping station when one of the install functions, the remove and return function, or the swap function is completed at the nearby battery swapping station, based on the established communication with the nearby battery swapping station and the four-wheeler EV (102).
6. The EV battery system (100) as claimed in claim 5, wherein the EV battery system (100) comprises a robotic trolley assembly at each of a plurality of battery swapping stations (104), wherein when the four-wheeler EV (102) is positioned on a pre-defined spot on a ramp (606) of a battery swapping station, the robotic trolley assembly is configured to automatically perform one of the install functions, the remove and return function, or the swap function based on the instruction received from the electronic device (120).
7. The EV battery system (100) as claimed in claim 1, wherein the chassis (202) has a chassis structural member (106) having a front section and a rear section, and wherein the rear section is configured to support the add-on battery slot (110) at a rear side of the four-wheeler EV (102) and the front section is configured to support a fixed battery slot (124) for the fixed battery (108) at a front side of the four-wheeler EV (102).
8. The EV battery system (100) as claimed in claim 1, wherein the chassis (202) has a chassis structural member (106) having a front section and a rear section, and wherein the rear section is configured to support a fixed battery slot (124) for the fixed battery at a rear side of the four-wheeler EV (102) and the front section is configured to support the add-on battery slot (110) at a front side of the four-wheeler EV (102).
9. The EV battery system (100) of claim 1, wherein the chassis of the four-wheeler EV (102) underbody comprises a flexible multi-battery packaging configuration to accommodate and support installation of the fixed battery and the removable add-on battery independent of a battery size, a battery chemistry, or a battery capacity of the fixed battery or the removable add-on battery.
10. A four-wheeler EV (102), comprising:
a fixed battery (108) installed in a first section of a chassis (202) of a four-wheeler EV (102) underbody;
an add-on battery slot (110) configured to hold a removable add-on battery (112) in a second section of the chassis (202) of the four-wheeler EV (102) underbody;
a rapid-connect coolant connector set (114) configured to establish a detachable connection with the removable add-on battery (112) to maintain an operating temperature of the removable add-on battery (112) in a specified range during a ride of a four-wheeler EV (102);
a rapid-connect High-Voltage and Low-Voltage (HV-LV) connector set (116) configured to establish a detachable electrical connection with the removable add-on battery (112); and
a vehicle control unit (VCU) (118) configured to:
detect a presence of the removable add-on battery (112) when the removable add-on battery (112) is installed in the add-on battery slot (110) of the four-wheeler EV (102) underbody; and
automatically switch from the fixed battery (108) to the removable add-on battery (112) to power the four-wheeler EV (102) during the ride exclusively from the removable add-on battery (112).
11. A method (700) of battery swapping using an EV battery system (100), the method (700) comprising:
establishing a detachable connection with a removable add-on battery (112) of a four-wheeler EV (102) using a rapid-connect coolant connector set (114) of the EV battery system (100) to maintain an operating temperature of the removable add-on battery (112) in a specified range during a ride of the four-wheeler EV (102);
establishing a detachable electrical connection with the removable add-on battery (112) using a rapid-connect High-Voltage and Low-Voltage (HV-LV) connector set (116) of the EV battery system (100);
detecting, by a vehicle control unit (VCU) (118) of the four-wheeler EV (102), a presence of the removable add-on battery (112) when the removable add-on battery (112) is installed in the add-on battery slot (110) of the four-wheeler EV (102) underbody; and
automatically switching, by the VCU (118), from the fixed battery (108) to the removable add-on battery (112) to power the four-wheeler EV (102) during the ride exclusively from the removable add-on battery (112).