Battery Module Docking with Three-Stage Mechanical Guiding
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Solution Overview
Problem
The challenge of securely and efficiently docking large and heavy battery modules on vehicle chassis with high precision is unresolved, leading to difficulties in positioning and assembling energy storage systems in heavy-duty vehicles.
Innovation Solution
A method involving a sequential guiding process using male and female connecting elements with varying tolerances in X and Z directions, including a first rough guiding followed by second and third finer guidings, to achieve precise alignment and connection of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-stage docking method is used for battery modules, then the docking process is simple, but the positioning precision and alignment accuracy are insufficient
Solution Approach 1:
The docking process is segmented into three sequential guiding stages: rough guiding (coarse positioning), intermediate guiding (fine positioning), and final guiding (precise positioning). Each stage uses connecting elements with appropriate tolerance levels for that stage, transforming a single complex high-precision requirement into three manageable sequential steps that collectively achieve high docking precision without requiring all elements to be simultaneously complex
Solution Approach 2:
The rough guiding stage performs preliminary positioning of battery modules before the finer guiding stages. By establishing approximate alignment first with larger tolerances, the system prepares the modules for subsequent precise positioning, preventing the need for all guiding elements to achieve full precision simultaneously and simplifying the overall system design
2Productivity
If traditional docking methods are used for large battery modules, then the assembly process is straightforward, but the docking time and operational efficiency are reduced
Solution Approach 1:
The docking process is divided into three sequential guiding stages that can be executed efficiently in sequence. This segmentation allows parallel preparation of connecting elements for different stages and enables workers to focus on one positioning task at a time, improving overall docking efficiency while reducing total docking time compared to attempting single-stage precise positioning
Solution Approach 2:
The system changes tolerance parameters across the three guiding stages: larger tolerances in rough guiding accommodate faster, less precise positioning actions, while progressively tighter tolerances in intermediate and final guiding stages achieve precise alignment. This parameter progression optimizes the balance between speed and precision at each stage, improving overall productivity
3Manufacturing precision
If battery modules are positioned with high precision requirements, then the alignment accuracy is improved, but the difficulty of positioning and assembly increases
Solution Approach 1:
The high precision alignment requirement is segmented across three guiding stages with progressively tightening tolerances. Each stage presents a manageable positioning challenge rather than requiring operators to achieve full precision in a single difficult operation, making the overall process easier to execute while achieving high final alignment accuracy
Solution Approach 2:
Rough guiding performs preliminary alignment that brings battery modules into approximate position before finer guiding stages. This preliminary action reduces the difficulty of subsequent precise positioning by eliminating the need to achieve full precision from an unaligned starting position, making the overall positioning process more manageable
4Quantity of substance
If multiple battery modules are connected to increase energy storage capacity, then the vehicle operation range is extended, but the complexity of docking and assembling increases
Solution Approach 1:
The assembly of multiple battery modules uses segmented guiding stages that can be replicated for each module connection. This standardization of the three-stage process across multiple modules reduces overall assembly complexity compared to customizing each connection, enabling scalable energy storage expansion while maintaining manageable assembly complexity through process repetition
Data Source
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AI summary
A method for docking of a first and a second battery module of an energy storage arrangement on a respective side of a vehicle chassis, the method comprising; a) guiding the first and the second battery modules inwardly towards the vehicle chassis, b) activating a mechanical guiding for guiding the battery modules inwardly towards the vehicle chassis; - a first rough guiding, wherein a first male connecting element is provided on a connecting side of one of the battery modules and a matching first female connecting element is provided on a connecting side of the other one of the battery modules and wherein the battery modules are guided in the X- and Z-direction to a first relative position; - a second finer guiding for setting a predetermined X-positions of the battery modules; and - a third finer guiding for setting a predetermined Z-position of the battery modules.