Cylindrical Battery Alignment Plates for Passive Orientation Control

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Solution Overview

Problem

Existing battery charging devices face challenges in aligning secondary batteries efficiently, leading to potential failures and increased size and manufacturing costs due to the need for direction detection mechanisms and power-driven conveyance systems.

Innovation Solution

A battery aligning device with regulating plates having a non-linear cross-section and specific intervals that allow aligned batteries to pass while preventing non-aligned batteries from progressing, eliminating the need for direction detection and power mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a robot arm is used to align batteries, then alignment can be achieved, but the device size and manufacturing cost increase due to direction detection mechanisms and power mechanisms

Engineering Contradiction:
Improvebattery alignmentVSAvoiddevice size and cost
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The battery aligning device utilizes the battery's own weight and gravity to achieve automatic alignment. The inclined guide walls and regulating plates form a self-aligning mechanism that requires no external power source or direction detection, allowing batteries to orient themselves correctly as they move through the alignment chamber

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces complex powered mechanical systems (robot arms, motors, sensors) with a passive mechanical structure consisting of inclined guide walls and regulating plates that use gravity and geometry to achieve alignment, eliminating the need for power mechanisms and direction detection systems

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If a conveying device with vibration mechanism is used to align batteries, then alignment can be achieved, but the device size and manufacturing cost increase due to power mechanisms and sufficient conveyance path requirements

Engineering Contradiction:
Improvebattery alignmentVSAvoiddevice size and cost
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The alignment mechanism uses the battery's own weight and the inclined geometry of the guide walls to achieve alignment automatically, eliminating the need for external vibration mechanisms or power sources. The structure itself provides the alignment function through its geometric configuration

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent employs inclined guide walls that create a sloped path, allowing batteries to naturally roll or slide into the correct orientation under gravity. The curved or angled surfaces guide the batteries without requiring vibration or powered conveyance mechanisms

Inventive Principle:
Principle #14Spheroidality (Curvature)

3Productivity

If batteries are not aligned in direction before charging, then charging can proceed, but failures or abnormal stops occur due to improper battery placement in slots

Engineering Contradiction:
Improvecharging operationVSAvoidcharging reliability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The alignment device performs preliminary alignment of batteries before they are transferred to the charging slots. By pre-aligning the batteries in the correct orientation using the inclined guide walls and regulating plates, the system ensures that only properly oriented batteries reach the charging position, preventing charging failures

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The alignment chamber with its inclined guide walls and regulating plates serves as an intermediary between the battery input and the charging slots. This intermediate structure ensures that batteries are properly oriented before entering the charging process, acting as a filter that prevents misaligned batteries from reaching the charging position

Inventive Principle:
Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The device effectively aligns batteries without additional mechanisms, resulting in a compact and cost-effective solution for aligning batteries of different sizes.

Implementation Method 1

a plurality of regulating plates 3a to 3e which constitute a slit in a path from the inlet 22 to the outlet 23... has a cross-section perpendicular to a supporting direction with a non-linear shape... in an interval between one of the two regulating plates 3a to 3e facing each other, a facing interval between the surfaces is larger than a diameter of the first cylindrical battery B1

Methodology Applied
Scientific EffectGeometric constraint: Geometry

Data Source

PatentEP3483977B1Battery aligning device
Publication Date: 2023.10.04 FDK CORP
  • EP3483977B1 patent drawingFigure 1~2
  • EP3483977B1 patent drawingFigure 3~4
  • EP3483977B1 patent drawingFigure 5

AI summary

A battery aligning device (1) includes an inlet (22) through which a first cylindrical battery (B1) is input, an outlet (23) from which the first cylindrical battery (B1) is discharged, regulating plates (3a to 3e) constituting a slit in a path from the inlet (22) to the outlet (23), and a support member (2) which supports one end portion (30) and the other end portion (31) of each of the regulating plates (3a to 3e), in the regulating plates (3a to 3e), a length from the one end portion (30) to the other end portion (31) is longer than a length (L1) of the first cylindrical battery (B1), an X-Z cross-section has a nonlinear shape, in an interval between the one regulating plate (3c) and the other regulating plate (3d), a facing interval (J1) between surfaces is larger than a diameter (D1) of the first cylindrical battery (B1), and when a line segment (PQ) having the same length as that of the first cylindrical battery (B1) is in contact with the regulating plate (3c) at a point (Q) and a point (R) on the X-Z cross-section, a distance between the line segment (PQ) and the regulating plate (3d) is arranged at an interval smaller than the diameter (D1) of the first cylindrical battery (B1) .