Battery Module Guide Rails and Protrusion Stops
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Solution Overview
Problem
Existing power storage devices face challenges in efficient installation, maintenance, and inspection due to the heavy weight of battery modules, which requires significant labor and poses safety risks, especially when transferring and connecting multiple modules with complex cable connections.
Innovation Solution
A power storage device with a chassis design that includes guide rails and protrusion portions to facilitate safe insertion and removal of battery modules, preventing drops and incorrect insertion, and simplifying the connection process through a structured arrangement of connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If battery modules are housed in a housing case for compact arrangement, then space utilization is improved, but the weight and complexity of handling multiple heavy modules increases
Solution Approach 1:
The battery system is divided into multiple independent battery modules that can be individually handled, transferred, and replaced. Each module contains its own battery cells and is designed as a separate unit with standardized interfaces, enabling modular assembly and disassembly without handling the entire battery system at once.
Solution Approach 2:
A housing case with guide rails and positioning structures serves as an intermediary mechanism that facilitates the safe and accurate insertion/removal of battery modules. The guide rails and protrusion portions act as intermediaries that control the movement path and positioning of heavy modules during transfer operations.
2Reliability
If guide rails and positioning structures are added to prevent battery module drops, then safety is improved, but device complexity increases
Solution Approach 1:
The guide rails and positioning structures utilize asymmetric geometries where protrusion portions on battery modules engage with corresponding recesses in the chassis at specific angles and positions. This asymmetric design provides automatic positioning and prevents incorrect insertion while maintaining structural efficiency.
Solution Approach 2:
The guide rails and positioning structures are designed to distribute mechanical loads evenly across multiple contact points during battery module insertion and removal. This equipotential load distribution prevents stress concentration and reduces the overall structural complexity required to handle heavy modules safely.
3Ease of operation
If connectors are arranged in a structured manner to simplify connections, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
Connectors are pre-positioned and pre-aligned on battery modules during the manufacturing process, with their locations and orientations predetermined by the modular design. This preliminary action ensures that when modules are installed, connectors are already in the correct positions, simplifying the connection process and reducing the need for complex alignment procedures during installation.
Data Source
AI summary
A power storage device including a battery containing body and a first guide rail for receiving a first end portion on a lower side of the body and a second guide rail for receiving a second end portion on an upper side of the body. The first guide rail includes a higher side plate and a lower side plate and extend in an insertion direction, and a receiving portion including a stopper. A first protrusion portion that, when removing the battery containing body, engages with the stopper, thereby preventing the battery containing body from dropping A second protrusion portion that, when the battery containing body is turned upside down, engages with the higher side plate, thereby blocking the insertion. When an attempt to remove the battery containing body from the receiving portion is made, the second protrusion portion engages with the stopper, thereby preventing it from dropping.