Detection Accuracy
Laser sensors are required at every key step, including gripping, transfer, and placement, to confirm that each mechanism has reached the correct position.
Hydrogen Refueling and Battery Swap
High-precision laser positioning aligns battery packs and hydrogen refueling interfaces, ensuring reliable docking during heavy-truck battery swap and hydrogen refueling while resisting vibration interference.
Process Overview
Ceiling-mounted battery swapping is one of the mainstream approaches for heavy-truck battery swap stations. It works much like a gantry crane: the swap robot travels along overhead rails, moves above the vehicle, and precisely grips and replaces the battery pack.
Scenario Pain Points
Adaptability to Complex Environments
The sensor must operate reliably across a wider temperature range to meet real operating conditions in battery swap stations across different regions.
Environmental Interference
The sensor must resist strong ambient light and identify battery-pack housings made from different materials and colors.
GATPOR Solution
GATPOR LD200 laser distance sensors are based on dToF technology. With high accuracy, strong ambient-light immunity, and wide-temperature operation, they can complete arrival and position confirmation at key nodes in the battery swapping process.
Customer Value
GATPOR LD200 laser distance sensors deliver high-precision positioning below 1 mm and are suitable for most battery swap station types, including top-lift and side-swap stations. With laser positioning, the system can accurately locate the battery compartment and shorten the full battery replacement process to within five minutes.
Related Products
LD200 Series Laser Distance Sensor
High Precision
Success Cases
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Process Overview
Heavy-truck hydrogen cylinder swapping replaces depleted hydrogen cylinder packs on fuel-cell heavy trucks. Unlike charging, this uses a vehicle-cylinder separation model: after the vehicle enters the station, automated equipment removes the depleted cylinder pack and installs a full one, typically within 3 to 5 minutes. The equipment includes cylinder hoisting mechanisms, positioning platforms, AGV carriers, and locking mechanisms. Precise docking between the hydrogen cylinder and vehicle interface, stable hoist movement, and accurate vehicle stopping all depend on high-precision position sensing.
Scenario Pain Points
Detection Accuracy
The hydrogen cylinder interface and vehicle interface must be aligned precisely. An error greater than +/-2 mm may compromise sealing and create a hydrogen leakage risk.
Complex Environment
Hydrogen swap stations are often outdoors or semi-open, with dust, rain, fog, and strong light that challenge sensor stability.
Vehicle Parking Deviation
Different vehicle models and load states create parking deviations, affecting automatic alignment of the hydrogen swap mechanism.
High Maintenance Difficulty
Hydrogen swap equipment runs at high frequency. Contact sensors are prone to wear and require frequent calibration, reducing operating efficiency.
GATPOR Solution
GATPOR laser distance sensors use non-contact, high-precision, interference-resistant ToF laser ranging to provide full-process position sensing for hydrogen swapping.
Vehicle positioning
Measure the distance between the vehicle and station reference line in real time to guide accurate parking or automatic position correction.
Hydrogen cylinder hoisting
Monitor the distance between the lifting fixture and cylinder top in real time, control hoisting speed, prevent collisions, and confirm that the cylinder is fully lifted or seated.
Interface docking
Precisely measure the relative position between the cylinder interface and vehicle interface, guiding robotic fine adjustment so the sealing surfaces fully match.
Safety protection
Monitor whether personnel or foreign objects enter hazardous areas and trigger safety interlocks to protect the operation.
Vehicle positioning
Measure the distance between the vehicle and station reference line in real time to guide accurate parking or automatic position correction.
Hydrogen cylinder hoisting
Monitor the distance between the lifting fixture and cylinder top in real time, control hoisting speed, prevent collisions, and confirm that the cylinder is fully lifted or seated.
Interface docking
Precisely measure the relative position between the cylinder interface and vehicle interface, guiding robotic fine adjustment so the sealing surfaces fully match.
Safety protection
Monitor whether personnel or foreign objects enter hazardous areas and trigger safety interlocks to protect the operation.
Customer Value
Non-contact laser measurement avoids mechanical wear and false-trigger risks. Real-time monitoring of hoisting distance and interface alignment reduces collision and leakage risks. Safety interlocks stop the equipment when personnel enter the work zone. ToF laser ranging resists ambient light, operating stably under 100 kLux strong light, and withstands dust, rain, fog, and outdoor lighting. Sensor data can be uploaded to the station control system for trajectory playback, alarm records, equipment health management, and troubleshooting.
Related Products
LD200 Series Laser Distance Sensor
High Precision
Get a tailored solution