DESC:SWAPPABLE POWER CHARGER FOR CHARGING BATTERY PACK
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202221075285 filed on 25/12/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to electric vehicle charging systems. Particularly, the present disclosure relates to mechanisms for the safe swapping of battery packs in electric vehicle charging stations.
BACKGROUND
Electric vehicle (EV) charging systems have become increasingly important with the growing popularity of electric vehicles. Traditionally, such charging systems involve charging stations where vehicles are plugged in for a duration to recharge the battery packs of the vehicles. Further, an emerging trend in the domain is the development of charging stations designed for the swapping of uncharged battery packs with fully charged battery packs. The aforementioned method significantly reduces the waiting time for EV users, as the users can readily exchange a depleted battery pack with a fully charged battery pack, thus enabling continuous use of the EV without the typical delay associated with conventional charging methods.
However, the process of swapping battery packs at charging stations presents various challenges. The primary concern is ensuring a safe and efficient swapping, particularly considering the high-power levels and the sophisticated nature of the battery pack technology involved. Further, when swapping a battery pack, especially one in a low charge state, there is a risk of electrical arcing, which not only poses a safety risk to users and service personnel but can also damage the electrical connections between the battery pack and the charging station, thereby potentially compromising the integrity and longevity of both the battery pack, the EV and the charging infrastructure.
Thus, there is an urgent need for an improved charging system that overcomes the one or more problems associated with the EV charging stations that enable the swapping of battery packs as set forth above.
SUMMARY
An object of the present disclosure is to provide a mechanism for electric vehicle charging stations for safe and efficient swapping of battery packs.
In accordance with first aspect of the present disclosure, there is provided a swappable power charger for charging a battery pack, swappable power charger comprising a charging compartment receives the battery pack, a detection unit detects the presence of the battery pack in the charging compartment, a switching unit enables and/or disables an electrical connection between the battery pack and a power source, an input interface receives an external command and a control unit. The control unit controls the switching unit to enable supply of electric energy from the power source to the battery pack if presence of the battery pack is detected and disable supply of electric energy from the power source to the battery pack if the external command is received or at least one pre-set condition is met.
The present disclosure provides a mechanism for electric vehicle charging stations that significantly enhances safety during the battery swapping process. Advantageously, the mechanism prevents electrical arcing, which is a common issue in conventional battery swapping methods, thereby increasing safety associated with battery pack swapping. Furthermore, the disclosed mechanism improves the overall efficiency of the charging process, thus, enabling a quicker reliable battery pack swapping. Advantageously, the mechanism also enables to extend the lifespan of both the battery packs and the charging station (such as, the lifespan of electromechanical connectors of the charging station), as the mechanism minimizes wear and tear caused by unsafe disconnection and reconnection practices. Furthermore, the disclosed mechanism is user-friendly and simplifies the battery pack swapping process for EV drivers. Additionally, the disclosed mechanism offers increases compatibility with a variety of battery pack designs, making the mechanism versatile for different types of EVs and charging stations.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a circuit diagram of a swappable power charger for charging a battery pack, 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
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 recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a motor of an electric vehicle and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms ‘electric vehicle’, ‘EV’, and ‘EVs’ are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheeler, electric three-wheeler, electric four-wheeler, electric pickup trucks, electric trucks and so forth.
As used herein, the term 'swappable power charger' refers to a charging system or apparatus designed to facilitate the exchange or replacement of battery packs in EVs or other devices requiring stored electrical energy. The term encompasses charging units capable of allowing users to swap a depleted battery pack with a fully charged one, thus reducing the waiting time typically associated with recharging batteries. The 'swappable power charger' includes mechanisms for safely and efficiently removing and replacing battery packs, and the charger is equipped with features that ensure proper alignment, secure fitting, and optimal charging conditions for the battery packs. The term is inclusive of chargers used for a variety of electric vehicles, including electric two-wheelers, three-wheelers, four-wheelers, electric pickup trucks, electric trucks, and other electrically powered vehicles or equipment. Additionally, the 'swappable power charger' may also refer to charging systems implemented in stationary settings, such as charging stations, as well as portable or mobile units.
As used herein, the term 'battery pack' refers to an assembly of individual cells or batteries arranged and connected to deliver electrical power for various applications, particularly in electric vehicles EVs and electronic devices. The 'battery pack' may consist of multiple electrochemical cells, which can be based on various chemistries including, but not limited to, lithium-ion, lead-acid, nickel-metal hydride, or solid-state batteries. Such cells are typically arranged in series, parallel, or a combination of both to achieve the desired voltage, capacity, and power output. The 'battery pack' is designed to store electrical energy and provide a supply of power for propulsion in electric vehicles, as well as to operate electronic devices and systems. The 'battery pack' the range, performance, and charging capabilities of the EV. The term also encompasses the structural housing, electronic control systems, cooling mechanisms, and safety features integrated with the cells to form a complete and functional unit. The 'battery pack' may vary in size, shape, and capacity depending on its intended use, from small packs used in portable electronics to larger, more complex assemblies found in electric vehicles and stationary energy storage systems.
As used herein, the term 'charging compartment' refers to a specific section or area within a charging system, such as a swappable power charger, designed to house and secure a battery pack during the charging process. The 'charging compartment' is structured to accommodate the physical dimensions of the battery pack and is equipped with the necessary electrical connections for charging. The compartment may include features that align the battery pack correctly, ensure a stable and secure placement, and facilitate easy insertion and removal of the battery pack. The design of the 'charging compartment' is critical for maintaining proper electrical contact and can also include safety features to protect against overheating, short-circuiting, and other electrical hazards. The 'charging compartment' may vary in size and configuration depending on the type and dimensions of the battery packs it is designed to charge.
As used herein, the term 'detection unit' refers to a component or system within a swappable power charger that is responsible for identifying the presence and status of a battery pack within the charging compartment. The 'detection unit' uses sensors or other detection mechanisms to ascertain whether a battery pack is properly positioned for charging and may also gather data about the characteristics of the battery pack such as type, state of charge, temperature, or other relevant parameters. The information gathered by the 'detection unit' is used to initiate the charging process, adjust charging parameters, or provide safety checks to prevent charging under unsafe conditions.
As used herein, the term 'switching unit' refers to a component within a swappable power charger that controls the electrical connection between the battery pack and the power source. The 'switching unit' is responsible for enabling or disabling the flow of electric current for the purpose of starting or stopping the charging process. The switching unit acts based on signals or commands received from a control unit, which may be triggered by recognition by the detection unit of presence of the battery pack or other pre-set conditions. The 'switching unit' plays a crucial role in ensuring the safety and efficiency of the charging process, protecting against overcharging, short circuits, and other electrical issues. The switching unit can include relays, switches, circuit breakers, or other electronic components capable of managing high power levels as required in EV charging.
As used herein, the term 'input interface' refers to a component of the swappable power charger that facilitates the reception of external commands or inputs. The 'input interface' serves as a communication gateway between the user or an external system and the charger. The input interface can be integrated in various forms, including physical buttons or touchscreens on the charger, or remote interfaces such as a wireless or portable device such as a smartphone. Further, the implementation of the input interface as a wireless or portable device offers enhanced convenience and flexibility, allowing users to interact with the charger from a distance, such as, using a dedicated application. The 'input interface' can receive a range of commands, from initiating or stopping the charging process to selecting specific charging parameters. The versatility of the 'input interface', particularly in wireless or smartphone-integrated form is essential in modern charging systems, providing user-friendly operation and enabling advanced functionalities like remote monitoring or scheduling of charging sessions.
As used herein, the term 'control unit' refers to a central processing component within a swappable power charger that controls the operation of the charger based on input from various sources. The 'control unit' manages the functioning of the charger by processing signals from the detection unit, commands received through the input interface, and other relevant data. The control unit is responsible for controlling the switching unit to enable or disable the electrical connection between the battery pack and the power source, depending on the detected conditions or user commands. The 'control unit' can also adjust charging parameters based on the characteristics of the battery pack or other pre-set conditions, ensuring optimal charging efficiency and safety. The implementation of the 'control unit' is important for intelligent charging management, as the control unit provides the necessary logic and decision-making capabilities to handle various scenarios.
Figure 1, in accordance with an embodiment describes a circuit diagram of a swappable power charger 100 for charging a battery pack 102. The swappable power charger 100 is designed as an apparatus for facilitating the efficient and safe swapping of battery packs in electric vehicle charging stations. The swappable power charger 100 is structured to accommodate the specific requirements of electric vehicle battery packs, ensuring compatibility and ease of use. The swappable power charger 100 comprises a charging compartment 104 that receives the battery pack 102. The charging compartment 104 within the swappable power charger 100 is a designated area specifically designed to receive and securely hold the battery pack 102. The charging compartment 104 aligns the battery pack 102 with the necessary connections for charging the battery pack 102. The design of the charging compartment 104 ensures a secure fit, reducing the risk of improper placement and potential damage to the battery pack 102.
The swappable power charger 100 comprises a detection unit 106 that detects the presence of the battery pack 102 in the charging compartment 104. The detection unit 106 in the swappable power charger 100 is responsible for detecting the presence of the battery pack 102 in the charging compartment 104. The detection unit 106 enables to initiate the charging process and ensures that charging does not occur when no battery pack 102 is present within the charging compartment 104, thus preventing energy wastage and potential safety hazards.
The swappable power charger 100 comprises a switching unit 108 that enables and/or disables an electrical connection between the battery pack 102 and one or more electrical load (e.g., motor, cooling system, etc.) and vehicle management system. The switching unit 108 in the swappable power charger 100 plays a pivotal role in enabling or disabling the electrical connection between the battery pack 102 and the power source 110. The switching unit 108 ensures that the charging process is performed in a controlled and safe manner. The switching unit 108 also enables to quickly disconnect the power in case of any anomalies or as per specific operational requirements. Consequently, the switching unit 108 increases safety associated with swapping of the battery pack 102 for charging the battery pack 102.
The swappable power charger 100 comprises a power source 110. The power source 110 provides the necessary electric energy for charging the battery pack 102. The power source 110 further ensures a consistent and optimized charging process. As shown, the power source 110 is implemented as an alternating current (AC) power source. Optionally, the swappable power changer 100 comprises an inverter for converting the AC received from the power source 110 into direct current (DC) for storage within the battery pack 102.
The swappable power charger 100 comprises an input interface 112 that receives an external command. The input interface 112 enables to receive external commands that can influence the operation of the charger, such as, from a user to enable initiation of charging of the battery pack 102. input interface 112 further allows integration with automated systems, providing flexibility and control over the charging process, such as, in a commercial battery pack charging infrastructure responsible for charging multiple battery packs simultaneously.
The swappable power charger 100 comprises a control unit 114 that controls the switching unit 108 to enable supply of electric energy from the power source 108 to the battery pack 102 if presence of the battery pack 102 is detected and disable supply of electric energy from the power source 108 to the battery pack 102 if the external command is received or at least one pre-set condition is met. The control unit 114 controls the switching unit 108, such as, by activating the switching unit 108 to enable the supply of electric energy from the power source 110 to the battery pack 102 when the presence of the battery pack 102 is detected. Further, the control unit 114 disables the supply of electric energy from the power source 110 to the battery pack 102 upon receiving an external command or when at least one pre-set condition is met. Consequently, the control unit 114 ensures the efficient and safe operation of the swappable power charger 100 by coordinating the various components and processes involved in the charging of the battery pack 102.
In an embodiment, at least one pre-set condition is selected from: a State of Charge (SoC) of the battery pack 102, a State of Health (SoH) of the battery pack 102, an overheating condition and a determined fault in the battery pack 102. The swappable power charger 100 can detect and respond to pre-set conditions such as the SoC and the SoH of the battery pack 102. The SoC is an indicator of the remaining energy in the battery pack 102, while the SoH provides information about the overall condition and efficiency of the battery pack 102. Additionally, the swappable power charger 100 identifies overheating conditions and any determined faults within the battery pack 102. Such monitoring of conditions associated with battery pack 102 enables the swappable power charger 100 to optimize the charging, enhance battery longevity and prevent potential safety issues by adjusting the charging process in real-time based on the aforesaid parameters.
In another embodiment, the charging compartment 104 comprising a hinged door for controlling an access of the charging compartment 104. The hinged door provides a physical barrier that safeguards the battery pack 102 from environmental factors and accidental impacts. Further, the hinged door enables to prevent unauthorized access to the battery pack 102 during charging or storage of the battery pack 102. Such prevention of unauthorized access to the battery pack 102 is important in public or semi-public settings where the risk of tampering or theft of the battery pack 102 (such as in a publicly accessible charging station) might be higher. The hinged door is integrated with the overall structure of the swappable power charger 100 ensuring that the hinged door does not impede the functionality of the swappable power charger 100 while ensuring safety and security of the battery pack 102.
In an embodiment, the hinged door is in a locked position to prevent dislodgement of the battery pack 102 during charging. The maintaining of the hinged door in the locked position enables to prevent the unintended dislodgement or removal of the battery pack 102 during the charging process. Consequently, the maintaining of the hinged door in the locked position is beneficial in public charging stations associated with a higher risk of tampering or accidental disturbance. The locked hinged door ensures a stable and uninterrupted charging connection by securing the battery pack 102 in place. Consequently, the stability is important for the safety of the charging process as well as for maintaining the integrity of the electrical connections, which could be damaged by movement or jarring of an unsecured battery pack 102. The locking mechanism can be implemented as a key lock, a combination lock, or even an electronic lock that could be integrated with a user authentication system. Such a flexibility allows customization according to the specific requirements of the environment in which the swappable power charger 100 is deployed.
In another embodiment, the charging compartment 104 comprises a cooling system for regulating a temperature of the battery pack 102. The cooling system enables to manage the thermal environment of the battery pack 102 during charging. It will be appreciated that the battery pack 102 may become heated during charging and discharging cycles. Further, excessive heating of the battery pack 102 can lead to reduced efficiency, potential damage, or even safety hazards. The cooling system in the charging compartment 104 regulates the temperature, thereby, ensuring that the battery pack 102 remains within a safe and optimal temperature range during charging. Consequently, the cooling system enhances the safety of the swappable power charger 100 while also contributing to maintaining the health and longevity of the battery pack 102 by preventing overheating and thermal stress.
In an embodiment, the charging compartment 104 comprises a retractable sliding arrangement. The retractable sliding arrangement enhances the user experience by simplifying the process of inserting and removing the battery pack 102 by allowing the battery pack 102 to glide smoothly into and out of the charging compartment 104, thereby reducing the physical effort required by the user and minimizing the risk of improper alignment or connection. The retractable sliding arrangement is beneficial in reducing wear and tear on both the battery pack 102 and the charger 100 by ensuring a controlled and precise movement. Further, the retractable sliding arrangement enables to accommodate battery packs 102 of varying sizes into the charging compartment 104, thereby increasing the versatility of the swappable power charger 100.
In another embodiment, the detection unit 106 detects a characteristic of the battery pack 102 and a condition of the battery pack 102, wherein at least one of the detected characteristics and the condition is used to adjust at least one charging parameter. The detected characteristic may include parameters such as voltage, current, temperature, or other relevant battery metrics. Further, the swappable power charger 100 can adjust the charging parameters based on the detected information. For example, if the detection unit 106 senses that the battery pack 102 is already partially charged, the control unit 114 (connected to the detection unit 106) may adjust the charging rate to prevent overcharging. Similarly, if the battery pack 102 is at a higher temperature, the control unit 114 might lower the charging rate or activate additional cooling to maintain optimal conditions. Consequently, the detection unit 106 enables to ensure more efficient energy use and enhances the safety and longevity of the battery pack 102.
In an embodiment, the charging compartment 104 comprises a shock-absorbing unit. The presence of the shock-absorbing unit is important in environments where the swappable power charger 100 might be exposed to physical shocks, vibrations, or other forms of mechanical stress. Further, the shock-absorbing unit provides a cushioning effect, thus protecting the battery pack 102 received into the charging compartment 104 from potential damage due to such impacts. The prevention of potential damage to the battery pack 102 is crucial for preserving the delicate internal components of the battery pack 102 that may be susceptible to damage from sudden jolts or vibrations. Consequently, the integration of the shock-absorbing unit into the swappable power charger 100 ensures a higher level of protection for the battery pack 102, thereby enhancing durability and reliability of the battery pack 102 in various operational settings.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different 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 where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

,CLAIMS:WE CLAIM:
1. 1. A swappable power charger (100) for charging a battery pack (102), comprising:
- a charging compartment (104) receives the battery pack (102);
- a detection unit (106) detects the presence of the battery pack (102) in the charging compartment (104);
- a switching unit (108) enables and/or disables an electrical connection between the battery pack (102) and a power source (110);
- an input interface (112) receives an external command; and
- a control unit (114) controls the switching unit (108) to:
- enable supply of electric energy from the power source (110) to the battery pack (102), if presence of the battery pack (102) is detected; and
- disable supply of electric energy from the power source (110) to the battery pack (102), if the external command is received or at least one pre-set condition is met.
2. The swappable power charger (100) as claimed in claim 1, wherein at least one pre-set condition is selected from: a State of Charge (SoC) of the battery pack (102), a State of Health (SoH) of the battery pack (102), an overheating condition and a determined fault in the battery pack (102).
3. The swappable power charger (100) as claimed in claim 1, wherein the charging compartment (104) comprising a hinged door for controlling an access of the charging compartment (104).
4. The swappable power charger (100) as claimed in claim 1, wherein the charging compartment (104) comprising a cooling system for regulating a temperature of the battery pack (102).
5. The swappable power charger (100) as claimed in claim 1, wherein the charging compartment (104) comprising a retractable sliding arrangement.
6. The swappable power charger (100) as claimed in claim 1, wherein the detection unit (106) detects a characteristic of the battery pack (102) and a condition of the battery pack (102), wherein at least one of the detected characteristic and the condition is used to adjust at least one charging parameter.
7. The swappable power charger (100) as claimed in claim 1, wherein the charging compartment (104) comprises a shock-absorbing unit.
8. The swappable power charger (100) as claimed in claim 3, wherein the hinged door is in a locked position to prevent dislodgement of the battery pack (102) during charging.