Abstract: The size of the battery pack and their arrangement decides the amount of total power and the voltage they can deliver to run a vehicle. Accessing the vehicle to replace battery packs safely are part of the design challenges for the operation of a successful battery replacement unit.

This invention is a complete end-to-end solution from when the vehicle enters the Battery Replacement Unit with a used (discharged completely or partially) battery pack and leaves with a charged battery pack based on the requirement of the driver. The communication with the driver is established at the user interface and business transaction is implemented. Along with the design aspects of the system, the invention gives a detailed operational sequence for the battery replacement unit.

Figure 1: Battery Pack Cart showing different size profiles for EV battery packs.

Figure 2: Movement flow of battery packs from delivery transport to storage racks.

Figure 3: Vehicle guidance system alignment layout at the exchange station.

Figure 4: Vehicle access system detailing underneath battery pack release mechanisms.