OF AN ELECTRIC VEHICLE

FIELD

[0001] Embodiments of the present disclosure relate to a system and a method for exchanging batteries of an electric vehicle. Embodiments of the present disclosure particularly relate to an exchange and charging of discharged batteries of electric vehicles, such as cars.

BACKGROUND

[0002] Electrically powered vehicles have an electric motor, wherein the required electrical energy is stored in a high-voltage storage unit. The high-voltage storage unit can be charged at a charging station of a home of the owner or at a public charging station. It is often advantageous for the user to have short charging times, so that the electrically powered vehicle can be quickly ready for use again.

[0003] In particular for urban areas, it has become apparent that public charging stations for electrically powered vehicles, especially cars, cannot be provided in sufficient numbers for various reasons. Another problem is that the electrically powered vehicles cannot be moved during the - sometimes considerable - charging times.

[0004] In order to solve these problems, it has been considered to charge replaceable batteries in charging stations and to replace discharged batteries, which are not permanently installed in the car, with charged batteries at these charging stations. However, an exchange of the batteries tends to be costly, space-consuming and prone to malfunctions.

[0005] In view of the above, new systems and methods for exchanging batteries of an electric vehicle that overcome at least some of the problems in the art are beneficial. SUMMARY

[0006] In light of the above, a system and a method for exchanging batteries of an electric vehicle are provided.

[0007] It is an object of the present disclosure to provide an efficient exchange of discharged batteries of an electric vehicle. In particular, it is an an object of the present disclosure to enable a fast and cost-saving replacement of the discharged batteries with low susceptibility to faults and to charge the discharged batteries as quickly as possible.

[0008] Further objects, aspects, benefits, and features of the present disclosure are apparent from the claims, the description, and the accompanying drawings.

[0009] According to an independent aspect of the present disclosure, a system for exchanging batteries of an electric vehicle is provided. The system includes a parking zone for the electric vehicle, wherein the parking zone may be moveable; a transport mechanism at least partially enclosing the parking zone, wherein the transport mechanism is configured to transport batteries from a first side of the parking zone to a second side of the parking zone along a transport path; and a charging mechanism configured to charge the batteries during a transportation thereof along the transport path.

[0010] According to a further independent aspect of the present disclosure, a method for exchanging batteries of an electric vehicle is provided. The method includes an unloading of a discharged battery from an electric vehicle at a first side of a parking zone, wherein the parking zone may be moveable; a transporting of the discharged battery from the first side to a second side of the parking zone along a transport path at least partially enclosing the parking zone; a charging of the discharged battery during the transportation thereof along the transport path; and a loading of a charged battery into the electric vehicle e.g. from the second side.

[0011] The first side and/or the second side of the parking zone may be beside (or lateral sides) of the parking zone. In other words, the first side and the second side may be opposite sides of the parking zone. Alternatively, the first side may be below the parking zone (or vehicle) and the second side may be besides the parking zone. Alternatively, the first side and the second side may be below the parking zone. Alternatively, the first side may be besides the parking zone (or vehicle) and the second side may be below the parking zone.

[0012] Embodiments are also directed at devices for carrying out the disclosed methods and include system parts for performing each described method aspect. These method aspects may be performed by way of hardware components, a computer programmed by appropriate software, by any combination of the two or in any other manner. Furthermore, embodiments according to the disclosure are also directed at methods for operating the described system. The methods include method aspects for carrying out every function of the system for exchanging batteries of an electric vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments. The accompanying drawings relate to embodiments of the disclosure and are described in the following:

FIG. 1 shows a schematic front view of a system for exchanging batteries of an electric vehicle according to embodiments described herein;

FIG. 2 shows a transport path according to embodiments described herein;

FIG. 3 shows a schematic front view of a system for exchanging batteries of an electric vehicle according to further embodiments described herein;

FIG. 4 shows a transport path according to embodiments described herein; FIG. 5 shows a schematic front view of a system for exchanging batteries of an electric vehicle according to further embodiments described herein; and

FIG. 6 shows a flowchart of a method for exchanging batteries of an electric vehicle according to embodiments described herein.

DETAILED DESCRIPTION OF EMBODIMENTS

[0014] Reference will now be made in detail to the various embodiments of the disclosure, one or more examples of which are illustrated in the figures. Within the following description of the drawings, the same reference numbers refer to same components. Generally, only the differences with respect to individual embodiments are described. Each example is provided by way of explanation of the disclosure and is not meant as a limitation of the disclosure. Further, features illustrated or described as part of one embodiment can be used on or in conjunction with other embodiments to yield yet a further embodiment. It is intended that the description includes such modifications and variations.

[0015] FIG. 1 shows a schematic front view of a system 100 for exchanging batteries of an electric vehicle 10 according to embodiments described herein. FIG. 2 shows a transport path TP of the system 100.

[0016] The system 100 includes a parking zone P for the electric vehicle 10; a transport mechanism 110 at least partially enclosing the parking zone P, wherein the transport mechanism 110 is configured to transport batteries 20 from a first side 103 of the parking zone P to a second side 105 of the parking zone P along a transport path TP; and a charging mechanism 120 configured to charge the batteries 20 during a transportation thereof along the transport path TP.

[0017] In some embodiments, the battery 20 may be pulled or pushed out of the vehicle by means of a sliding unit 130. [0018] Due to the transportation of the batteries from one side of the parking zone P to the other side, and further due to the charging of the batteries 20 during the transportation, an efficient exchange of discharged batteries can be provided. Further, the storage and charging of the batteries 20 requires a minimum of space and thus, the system 100 can be operated in a very small space. Furthermore, since the batteries 20 are charged immediately after their removal, the system 100 may store or require a smaller number of batteries compared to a configuration in which the batteries first have to be transported to a charging station e.g. by robots or manually. Moreover, the system 100 is less susceptible to faults and less costly to manufacture than e.g. mobile robots. Finally, the batteries 20 can be recharged at night with inexpensive electricity.

[0019] The electric vehicle can be an electric vehicle (BEV) or a plug-in hybrid vehicle (PHEV). The term vehicle includes passenger cars, trucks, buses, campers, motorcycles, etc., which are used to transport people, goods, etc. In particular, the term includes cars for the transport of persons.

[0020] The first side 103 and the second side 105 are opposite sides of the parking zone P. In particular, the electric vehicle 10 is parked in a space defined between the first side 103 and the second side 105 to exchange the discharged battery. The first side 103 can be a left side of the parking zone P and the second side 105 can be a right side of the parking zone P, or the first side 103 can be a right side of the parking zone P and the second side 105 can be a left side of the parking zone P, depending on a position of a viewer.

[0021] The first side and/or the second side of the parking zone may be beside (or lateral sides) of the parking zone. In other words, the first side and the second side may be opposite sides of the parking zone. Alternatively, the first side may be below the parking zone (or vehicle) and the second side may be besides the parking zone. Alternatively, the first side and the second side may be below the parking zone. Alternatively, the first side may be besides the parking zone (or vehicle) and the second side may be below the parking zone.

[0022] The transport path TP may extend above the parking zone P for a transportation of the batteries 20 from the first side 103 of the parking zone P to the second side 105 of the parking zone P. In particular, the transport path TP may have an inverted U-shape (P) which covers or encloses the parking zone P and the electric vehicle 10 parked therein. The inverted U-shape may be an essentially rectangular shape.

[0023] In some embodiments, the transport path TP has a first vertical section TPV1 at the first side 103 of the parking zone P, a first horizontal section TPH1 above the parking zone P, and a second vertical section TPV2 at the second side 105 of the parking zone P. The transport mechanism 110 may lift the discharged battery unloaded from the electric vehicle 10 along the first vertical section TPV1 to the first horizontal section TPH1. The battery 20 is then transported along the first horizontal section TPH1 and lowered along the second vertical section TPV2 while it is charged to be loaded into another electric vehicle.

[0024] The term “vertical direction” (“l”in FIG. 2) is understood to distinguish over “horizontal direction” (“2” in FIG. 2). That is, the “vertical direction” relates to a essentially vertical orientation e.g. of the sections of the transport path, wherein a deviation of a few degrees, e.g. up to 10° or even up to 15°, from an exact vertical direction or vertical orientation is still considered as “essentially vertical”. The vertical direction 1 can be substantially parallel to the force of gravity.

[0025] Likewise, the “horizontal direction” relates to an essentially horizontal orientation e.g. of the section(s) of the transport path, wherein a deviation of a few degrees, e.g. up to 10° or even up to 15°, from an exact horizontal direction or horizontal orientation is still considered as “essentially horizontal”. The horizontal direction 2 can be substantially perpendicular to the force of gravity.

[0026] According to some embodiments, which can be combined with other embodiments described herein, the transport mechanism 110 may include an unloading unit configured to unload discharged batteries from the electric vehicle 10 and/or a loading unit configured to load charged batteries into the electric vehicle 10. FIGs. 3 and 5 described later illustrate specific examples of the unloading unit and the loading unit, such as a sliding unit.

[0027] The unloading unit may unload the discharged battery from the electric vehicle 10 and move the discharged battery to a receptacle of the transport mechanism 110 which is used to transport the battery 20 from the first side 103 of the parking zone P to the second side 105 of the parking zone P. During the transport of the battery 20 from the first side 103 of the parking zone P to the second side 105 of the parking zone P, the charging mechanism 120 charges the discharged battery for example by means of sliding contacts. However, the present disclosure is not limited thereto, and other charging technologies may be used, such as inductive charging.

[0028] The charging mechanism 120 may be configured to charge the battery 20 fully or to a (e.g. predetermined) state of charge (e.g. < 100% of a maximal state of charge) until the battery 20 arrives at the second side 105 of the parking zone P. In other words, the battery 20 is a discharged battery when it is at the first side 103 of the parking zone P and is a charged battery when it is at the second side 105 of the parking zone P. The loading unit of the transport mechanism 110 may load the now-charged battery into another electric vehicle. The state of charge may be a predetermined state of charge or an arbitrary state of charge, e.g. if there is no fully charged battery available.

[0029] In this way, a plurality of batteries may be transported and charged simultaneously such that there is an essentially constant supply of charged batteries at the second side 105 of the parking zone P to serve a plurality of vehicles.

[0030] According to some embodiments, which can be combined with other embodiments described herein, the transport mechanism 110 includes a conveyor device, and in particular a conveyor belt, providing at least a part of the transport path TP. The conveyor belt can operate electrically. In some implementations, the transport mechanism 110 includes a rectangularly arranged circulating conveyor belt which operates based on the paternoster principle. The conveyor belt may have receptacles configured to accommodate batteries, which may be standardized vehicle batteries.

[0031] In the example illustrated in FIG. 2, the transport path TP, which may be provided by the conveyor belt, includes (or consists of) three sections or legs, namely the first vertical section TPV1 at the first side 103 of the parking zone P, the first horizontal section TPH1 above the parking zone P, and the second vertical section TPV2 at the second side 105 of the parking zone P. In this example, there is no second horizontal section below the parking zone P.

[0032] The first vertical section TPV1 and the first horizontal section TPH1 may be essentially perpendicular to each other. The second vertical section TPV2 and the first horizontal section TPH1 may be essentially perpendicular to each other. The first vertical section TPV1 and the second vertical section TPV2 may be essentially parallel to each other.

[0033] The term “essentially perpendicular” relates to an essentially perpendicular orientation e.g. of the sections, wherein a deviation of a few degrees, e.g. up to 10° or even up to 15°, from an exact perpendicular orientation is still considered as “essentially perpendicular”. Likewise, the term “essentially parallel” relates to an essentially parallel orientation e.g. of the sections, wherein a deviation of a few degrees, e.g. up to 10° or even up to 15°, from an exact parallel orientation is still considered as “essentially parallel”.

[0034] However, the present disclosure is not limited thereto and the transport path may have a rectangular shape, a rectangular shape with rounded edges, a half-circular shape, and the like.

[0035] In this 3-leg configuration, the conveyor belt cannot return to the bottom of the system, and thus, the conveyor belt may have a double structure in which one belt runs along a first path and a second path connected to each other, wherein the second path is e.g. an outer return path RP as it is illustrated in the example of FIG. 1. Thus, the conveyor belt may transport and optionally charge twice the number of batteries compared to a single-belt configuration.

[0036] Further, the 3 -leg configuration does not require the batteries to be removed and inserted from below of the electric vehicle 10. Accordingly, in some embodiments, the unloading unit may be configured to move laterally to laterally unload a discharged battery from the electric vehicle 10. In other words, the discharged battery is pulled or pushed sideways out of the (underbody of the) electric vehicle to one side. Likewise, the loading unit may be configured to move laterally to laterally load a charged battery into the electric vehicle 10. In other words, the charged battery is pushed into the electric vehicle 10 from the other side.

[0037] In the above configuration, the unloading unit may be provided at the first side 103 of the parking zone P rather than below the electric vehicle 10. Likewise, the loading unit may be provided at the second side 105 of the parking zone rather than below the electric vehicle 10.

[0038] The 3-leg configuration provides the beneficial effect that there is no need for a substructure to accommodate a lifting device.

[0039] According to some embodiments, which can be combined with other embodiments described herein, the at least one transport mechanism 110 is two or more transport mechanisms sequentially arranged in an essentially horizontal direction one behind the other, wherein the two or more transport mechanisms 110 provide two or more corresponding transport paths which are arranged in parallel. The arrangement thus forms a tunnel of transport mechanisms.

[0040] In other words, the system may be positioned multiple times one behind the other, so that charged batteries are available faster and/or more often. If for instance 30 batteries are in a charging process in the circulation, such a “tunnel” having e.g. ten transport mechanisms positioned one behind the other can constantly charge 300 batteries on the smallest possible space.

[0041] According to some embodiments, which can be combined with other embodiments described herein, the system can be configured to be mobile and can be moved around as required.

[0042] FIG. 3 shows a schematic front view of a system 200 for exchanging batteries of an electric vehicle 10 according to further embodiments described herein. FIG. 4 shows a transport path TP’ of the system 200. The system 200 and the system of FIG. 1 may be configured in a similar manner and thus, a description of similar or identical aspects is not repeated. [0043] In the example illustrated in FIGs. 3 and 4, the transport path TP’, which may be provided by a conveyor belt, has four sections or legs, namely the first vertical section TPV1 at the first side 103 of the parking zone P, the first horizontal section TPH1 above the parking zone P, the second vertical section TPV2 at the second side 105 of the parking zone P, and a second horizontal section TPH2 at a bottom portion of the parking zone P.

[0044] The first vertical section TPV1 and the first horizontal section TPH1 may be essentially perpendicular to each other. The second vertical section TPV2 and the first horizontal section TPH1 may be essentially perpendicular to each other. The first vertical section TPV1 and the second vertical section TPV2 may be essentially parallel to each other. The first horizontal section TPH1 and the second horizontal section TPH2 may be essentially parallel to each other.

[0045] The transport mechanism 110 may include an unloading unit configured to unload discharged batteries from the electric vehicle 10 and/or a loading unit configured to load charged batteries into the electric vehicle. For example, the unloading unit of the transport mechanism 110 may be configured to trigger a release of the discharged battery from the electric vehicle 10, in particular magnetically.

[0046] In some implementations, the unloading unit and/or the loading unit are provided at the bottom portion of the parking zone P corresponding to a position below the electric vehicle 10.

[0047] In some embodiments, the unloading unit and the loading unit are integrated in a single unloading/loading device 210, as it is illustrated in the example of FIG. 3. However, the present disclosure is not limited thereto, and the unloading unit and the loading unit can be provided as separate entities.

[0048] According to some implementations, the unloading unit is moveable in an essentially vertical direction 1 to unload the discharged battery from the electric vehicle 10 e.g. into an empty section of the conveyor belt. Additionally, or alternatively, the loading unit is moveable in an essentially vertical direction 1 to load a charged battery into the electric vehicle 10 from below the electric vehicle 10. [0049] For example, the unloading unit may receive the discharged battery and initiate the transport thereof along the transport path TP e.g. by putting or dropping the discharged battery on the conveyor belt.

[0050] At the same time, a partially or fully charged battery, e.g. the next battery coming out of the circulation, may be moved under the electric vehicle 10 and lifted by means of the loading unit. The charged battery may be inserted in a battery receiving device of the electric vehicle 10, where it is fixed or secured e.g. by means of a magnetic device. If necessary, the loading unit leaves the battery receiving device, and the next vehicle can be brought into the parking zone P to have its battery exchanged.

[0051] According to some embodiments, which can be combined with other embodiments described herein, the unloading unit and/or the loading unit may include (or be) a lifting device, such as a hydraulically extending and retracting telescopic device.

[0052] The unloading unit and/or the loading unit, such as the lifting device, may be recessed into (or built into) the floor. In order to provide enough moving range, a substructure can be provided in which the unloading unit and/or the loading unit is accommodated. Due to a space required by the substructure, at least one access ramp 30 to the parking zone P, and optionally a departure ramp, may be provided.

[0053] FIG. 5 shows a schematic front view of a system 300 for exchanging batteries of an electric vehicle 10 according to further embodiments described herein. The system 200 and the systems of FIGs. 1 to 4 may be configured in a similar manner and thus, a description of similar or identical aspects is not repeated.

[0054] The system 300 of FIG. 5 may have the 4-leg transport path TP’ illustrated in FIG. 3. However, in the present example the conveyor belt is used to receive and remove the battery from the electric vehicle. Thus, a separate mechanism such as the lifting device of FIG. 3 is not required. For example, the conveyor belt may run through an underfloor of the vehicle.

[0055] According to some embodiments, which can be combined with other embodiments described herein, the transport mechanism 110 includes a conveyor device, and in particular a conveyor belt, providing at least a part of the transport path. The conveyor belt can operate electrically. In some implementations, the transport mechanism 110 includes a rectangularly arranged circulating conveyor belt which operates based on the paternoster principle. The conveyor belt may have receptacles configured to accommodate batteries, which may be standardized vehicle batteries.

[0056] According to some embodiments, which can be combined with other embodiments described herein, the transport mechanism 110 may include a support structure for the conveyor belt, which may be configured to fix and move the conveyor belt to transport the batteries from the first side 103 of the parking zone P to the second side 105 of the parking zone P. The support structure, which may be a rectangular structure or device for fixing and moving the conveyor belt, is dimensioned in such a way that the electric vehicle 10 fits through it in terms of both width and height.

[0057] The support structure may include at least one opening through which respective batteries fit. The at least one opening can be used to remove batteries from the conveyor belt and/or to put (e.g. drop) batteries onto the conveyor belt. In some embodiments, the conveyor belt may extend below the electric vehicle (e.g. FIG. 4) and the at least one opening may be arranged in a center portion or middle of a lower part of the support structure. In particular, a position of the at least one opening may correspond to a position at which the discharged battery is unloaded from the electric vehicle 10 (e.g. by means of the conveyor) and/or a position at which a charged battery is loaded into the electric vehicle 10 (e.g. by means of the conveyor).

[0058] If the electric vehicle 10 is moved to a position over the at least one opening with a mobile battery still being fixed e.g. in an underbody of the electric vehicle 10, the battery can be released e.g. by means of a magnetic triggering device and moved or dropped through the opening onto an empty battery holder of the conveyor belt. In particular, the unloading unit of the transport mechanism may be configured to trigger a release of the discharged battery from the electric vehicle 10, in particular magnetically.

[0059] In terms of height, the support structure may be arranged in such a way that the batteries located on the lower leg of the conveyor belt are arranged at the same height as the discharged battery in the electric vehicle 10 which is to be replaced. In particular, the electric vehicle 10 may be moved into the support structure such that the battery to be replaced is located at the level of the batteries in the lower leg of the support structure, wherein there is no battery at this position of the conveyor belt or the opening in the frame (if necessary, side panels 12 of the electric vehicle 10 covering the battery compartment may be folded up beforehand). The battery located in the electric vehicle 10 is released and moved by the conveyor belt.

[0060] The next (or any other) charged battery is then moved on to the opening where it is picked up or fixed by a latching mechanism of the electric vehicle 10. The electric vehicle 10 then leaves the system 100 with the charged battery.

[0061] Meanwhile, the discharged battery removed from the electric vehicle 10 is moved further on the conveyor belt while it is charged e.g. by means of sliding contacts. After one rotation around the rectangular structure, it is available again in a partially or fully charged state for insertion into an electric vehicle coming from the other side.

[0062] According to some embodiments, which can be combined with other embodiments described herein, the conveyor belt can be extended by any number of loops arranged above, below or next to the transport rectangle.

[0063] FIG. 6 shows a flowchart of a method 600 for exchanging batteries of an electric vehicle according to embodiments described herein.

[0064] The method 600 includes in block 610 an unloading of a discharged battery from an electric vehicle at a first side of a parking zone; in block 620 a transporting of the discharged battery from the first side to a second side of the parking zone along a transport path at least partially enclosing the parking zone; in block 630 a charging of the discharged battery during the transportation thereof along the transport path; and in block 640 a loading of a charged battery into the electric vehicle.

[0065] In some embodiments, the configuration described above may be arranged in a mirrored manner, such as below the ground. [0066] The first side and/or the second side of the parking zone may be beside (or lateral sides) of the parking zone. In other words, the first side and the second side may be opposite sides of the parking zone. Alternatively, the first side may be below the parking zone (or vehicle) and the second side may be besides the parking zone. Alternatively, the first side and the second side may be below the parking zone. Alternatively, the first side may be besides the parking zone (or vehicle) and the second side may be below the parking zone.

[0067] According to embodiments described herein, the method for exchanging batteries of an electric vehicle can be conducted by means of computer programs, software, computer software products and the interrelated controllers, which can have a CPU, a memory, a user interface, and input and output means being in communication with the corresponding components of the system for exchanging batteries of an electric vehicle.

[0068] Due to the transportation of the batteries from one side of the parking zone to the other and the charging of the batteries during the transportation, an efficient exchange of discharged batteries can be provided. Further, the storage and charging of the batteries requires a minimum of space and thus, the system can be operated in a very small space. Furthermore, since the batteries are charged immediately after their removal, the system may store of a smaller number of batteries compared to a configuration in which the batteries first have to be transported to a charging station e.g. by robots or manually. Moreover, the system is less susceptible to faults and less costly to manufacture than e.g. mobile robots. Finally, the batteries can be recharged at night with inexpensive electricity.

[0069] While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.