Adjustable-Probe Battery OCV Testing on Automated Conveyors
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Solution Overview
Problem
Existing open circuit voltage (OCV) test systems for batteries suffer from low automation and detection efficiency, requiring manual intervention and limiting throughput.
Innovation Solution
An automated OCV test device featuring a conveying assembly, code scanning member, and adjustable test probes that allow simultaneous testing of multiple batteries, with adjustable spacing for compatibility with different models, and a secondary conveying line for failed batteries to maintain continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual testing methods are used for OCV testing, then device complexity is low, but automation degree and detection efficiency are low
Solution Approach 1:
The testing system is divided into multiple functional modules: a conveying assembly for battery transport, a code scanning member for identification, and a test member with multiple test probes for voltage measurement. Each module operates independently but coordinates through the conveying mechanism, enabling automated multi-point testing without requiring a monolithic complex system.
Solution Approach 2:
The conveying assembly serves as an intermediary mechanism that automatically transports batteries between the code scanning member and the test member. This intermediary component enables coordination between different testing functions, allowing the system to achieve high automation through a simple mechanical transport link rather than complex direct control mechanisms.
2Productivity
If single probe testing is used, then device complexity is low, but detection efficiency is low
Solution Approach 1:
Multiple test probes are merged into a single test member assembly that can simultaneously contact multiple batteries on the conveying assembly. This combining of multiple testing functions into one integrated component enables parallel testing of multiple batteries, significantly improving detection efficiency without requiring separate testing stations for each battery.
Solution Approach 2:
The test probes are arranged in the first direction (conveying direction) to correspond with the spatial arrangement of batteries on the conveying assembly. By organizing probes along the conveying direction rather than perpendicular to it, the system achieves simultaneous multi-point testing while maintaining a compact and simple test member structure.
3Adaptability or versatility
If fixed probe spacing is used, then device complexity is low, but adaptability to different battery models is limited
Solution Approach 1:
The spacing between adjacent test probes on the test member is made adjustable rather than fixed, allowing the system to adapt to different battery models with varying dimensions. This dynamic adjustability enables the same test member to accommodate multiple battery types by simply changing the probe spacing, enhancing versatility without requiring multiple specialized test members.
4Productivity
If sequential testing of batteries is used, then device complexity is low, but detection efficiency is low
Solution Approach 1:
The conveying assembly continuously transports batteries through the testing area, enabling uninterrupted sequential testing. By maintaining continuous motion of the conveying assembly, the system keeps the testing process flowing without idle time, improving throughput. The simplicity of the conveying mechanism ensures that continuous operation does not require overly complex system architecture.
Data Source
AI summary
An open circuit voltage test device for batteries is provided. The device includes a conveying assembly, a first code scanning member positioned above the conveying assembly, and a test member located downstream of the code scanning member in a first direction. The test member includes multiple test probes, and the spacing between adjacent test probes in the first direction is adjustable. Batteries are conveyed to the test position by the conveying assembly for automated voltage testing. The adjustable spacing between test probes allows alignment with battery positions on the conveying assembly, enabling simultaneous testing of multiple batteries and improving overall testing efficiency.