Battery Test Chamber Shelving for High-Density Cell Swapping

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current battery testing methods are inefficient due to the need for extensive setup and reconfiguration for each battery type, leading to low throughput and high capital equipment costs, as existing solutions are typically singular-use and require time-consuming battery swapping and reconnection processes.

Innovation Solution

The All Test Platform (ATP) enables high-density battery testing by using interchangeable sliding shelving and swappable circuit boards, allowing for rapid battery type changes without disconnecting external devices, maximizing test density and efficiency within an environmental test chamber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple batteries are tested simultaneously on a single shelf, then testing throughput increases, but battery density per chamber volume is limited and setup time increases

Engineering Contradiction:

Improvetesting throughputVSAvoidsetup time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system divides the testing space into multiple independent shelves that can be individually configured and rapidly installed. Each shelf is a separate module that can hold multiple batteries, allowing the chamber to be segmented into multiple testing zones simultaneously operational.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shelves are designed to be dynamically reconfigurable and rapidly installable within the chamber. The system transitions from static, fixed testing configurations to dynamic, adaptable shelving that can be quickly adjusted between different battery types and testing requirements.

Inventive Principle:

Principle #15Dynamics

2Reliability

If dedicated cabling is used for each battery type, then connection reliability is ensured, but system complexity and reconfiguration time increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcabling complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system employs universal connectors and standardized cabling interfaces that work across multiple battery types. This allows a single cabling infrastructure to serve multiple functions and battery configurations, eliminating the need for dedicated cables for each battery type while maintaining reliable connections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cabling system is designed to be dynamically reconfigurable through modular connectors and routing mechanisms. Cables can be quickly repositioned and reconnected between different battery configurations without requiring complete system reassembly, reducing both complexity and reconfiguration time.

Inventive Principle:

Principle #15Dynamics

3Reliability

If hard-wired battery connections are used, then electrical contact stability is improved, but ease of operation and battery swapping speed deteriorate

Engineering Contradiction:

Improveelectrical contact stabilityVSAvoidbattery swapping ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The electrical connection system is segmented into modular, quickly-connectable components. Each battery has dedicated connection points that interface with standardized terminals, allowing individual batteries to be connected or disconnected without affecting other connections in the system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connection terminals and electrical interfaces are pre-positioned and pre-configured on each shelf and battery. This preliminary arrangement ensures that when batteries are installed, electrical contacts are immediately stable and reliable without requiring complex wiring or adjustment during the swapping process.

Inventive Principle:

Principle #10Preliminary action

4Area of stationary object

If a single shelf configuration is used, then chamber space utilization is maximized, but adaptability to different battery types is reduced

Engineering Contradiction:

Improvechamber space utilizationVSAvoidbattery type adaptability

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

The chamber is divided into multiple shelf modules that can be independently configured. Each shelf is a separate unit that can be adjusted or reconfigured to accommodate different battery types, sizes, and testing requirements while maintaining high space utilization through vertical stacking and efficient arrangement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shelving system is designed to be dynamically reconfigurable between different battery configurations. Shelves can be adjusted in position, orientation, and density to adapt to various battery types while maximizing the use of available chamber space through optimized spatial arrangement.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11802914B1System for high density testing of batteries within an environmental test chamber

Publication Date: 2023.10.31 ASSOCIATED ENVIRONMENTAL SYSTEM INC

AI summary

The All Test Platform (ATP) provides provides a safe and easy way to test batteries within an environmental test chamber. The ATP enables rapid changing of batteries and battery types between tests, and provides the highest density per square foot of environmental test chamber space available for battery testing. The ATP combines multiple components critical for battery testing into a configurable, scalable, safe, and high density battery testing platform.