Adjustable Battery Compression Fixture for Multi-Angle Abuse Testing
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Solution Overview
Problem
Current mechanical abuse testing for lithium-ion batteries fails to simulate real-world inclined collisions due to the use of vertical compression, neglecting the complex stresses induced by inclined impacts, which affect internal short-circuit patterns and thermal runaway characteristics.
Innovation Solution
An adjustable tilt angle compression device that allows multi-angle compression testing with sensors to collect compressive force values at various angles, featuring a tilt adjustment mechanism, planar movement, and a liquid temperature regulation system to simulate diverse abuse scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If vertical compression is used for mechanical abuse testing, then the testing device structure is simple and easy to operate, but it cannot simulate real-world inclined collision states and fails to capture complex stresses
Solution Approach 1:
The testing device incorporates an adjustable tilt mechanism that allows the compression plate to be positioned at various angles (0°-90°) relative to the battery surface. This dynamic adjustment capability enables the device to simulate different collision scenarios, transforming a static vertical compression device into a versatile multi-angle testing system that adapts to real-world abuse conditions.
Solution Approach 2:
The invention introduces angular dimensionality to the compression testing by allowing the force application direction to vary from purely vertical to inclined at multiple angles. This adds a rotational degree of freedom to the testing mechanism, enabling simulation of oblique impacts that occur in actual vehicle accidents, thereby capturing both vertical and shear stress components.
2Measurement precision
If multi-angle compression testing is implemented, then comprehensive stress simulation is achieved, but the device complexity and sensor requirements increase
Solution Approach 1:
The device employs a universal sensor platform that can measure forces in multiple directions (vertical, horizontal, and inclined) using a unified measurement system. The load cell and sensor assembly are designed to capture force components along different axes simultaneously, providing comprehensive stress data through a single integrated sensing mechanism rather than requiring separate specialized sensors for each angle.
Solution Approach 2:
The invention introduces a force transmission mechanism with intermediate components (linkages, levers, or mechanical advantage systems) that translate the inclined compression force into measurable vertical and horizontal components. These intermediary mechanical elements facilitate the decomposition and measurement of complex multi-directional forces through standardized sensor interfaces.
3Reliability
If inclined compression is applied to simulate real-world impacts, then realistic abuse scenarios are replicated, but the deformation behavior differs from vertical compression requiring new testing protocols
Solution Approach 1:
The testing system incorporates programmable control that allows easy adjustment of testing parameters including tilt angle, compression rate, and force magnitude. By changing these parameters through software control rather than physical reconfiguration, the device can switch between different testing protocols (vertical, inclined, oblique) and simulate various abuse scenarios without complicating the operational procedure.
Data Source
AI summary
The present invention relates to the field of batteries, and particularly to a device and method for mechanical abuse testing of batteries. Existing devices apply compression vertically to the battery's force-bearing surface, which does not adequately simulate complex mechanical abuse during tilted scenarios. Specifically, they cannot compress the battery at multiple angles or collect compressive force values from different orientations. The invention provides an adjustable-tilt compression device for mechanical abuse testing of lithium-ion batteries. By tilting the battery support plate of the fixture, the device enables multi-angle compression and collection of force data from various angles, allowing for comprehensive testing of mechanical stresses encountered in real-world tilted abuse conditions. Additionally, the device supports testing at multiple points and under varying temperatures, enhancing the reliability and coverage of mechanical abuse assessments for battery safety evaluation.