Rotatable Battery Module Fixture for Isolated Multi-Surface Testing
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Solution Overview
Problem
High voltage battery modules for electric vehicles are difficult to maneuver and test due to their large and multi-layered nature, requiring specialized equipment for access to all surfaces and electrical isolation during sensitive measurements.
Innovation Solution
An electrical module rotisserie assembly with a rotatable frame structure, adjustable sliders, insulated joints, and modular clamps that accommodate different module sizes and designs, allowing for multiple rotational orientations and easy access to all surfaces while providing electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are made large and multi-layered to increase energy density, then energy storage capacity is improved, but difficulty to maneuver and access all surfaces for testing increases
Solution Approach 1:
The patent implements a rotatable frame structure that can rotate the battery module to multiple orientations (0°, 90°, 180°, 270°), transforming the static testing setup into a dynamic system. This allows all surfaces of large, multi-layered battery modules to be accessed for testing without manually repositioning the heavy modules, thereby maintaining ease of operation despite increased module size and complexity.
2Measurement precision
If specialized equipment is used to access all battery module surfaces for testing, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The rotatable frame structure serves multiple functions: it positions the battery module for access to all surfaces, provides electrical isolation through insulated joints, and enables comprehensive testing in a single integrated system. This multi-functional design improves measurement capability while avoiding the need for multiple separate specialized equipment, thereby controlling overall device complexity.
Solution Approach 2:
The patent introduces insulated joints as intermediary elements between the metal frame structure and the battery module. These joints provide electrical isolation, enabling sensitive electrical measurements without direct metal-to-metal contact, thus improving measurement precision while adding minimal complexity through the use of simple insulating components.
3Measurement precision
If electrical isolation is provided for sensitive measurements, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Insulated joints are introduced as intermediary elements between the metal frame structure and the battery module, providing electrical isolation through simple insulating materials. This approach achieves the required electrical isolation for sensitive measurements without creating complex isolation structures, as the joints are straightforward components that integrate easily into the existing frame design.
Data Source
AI summary
An electrical module rotisserie assembly for battery module handling and mechanical and electrical testing. The electrical module rotisserie assembly includes a rotatable frame structure with various sliders and insulated joints to provide an adjustable platform to fit any size electrical module and permit access to any surface of the electrical module for various testing and validation activities in an electrically-isolated manner. A plurality of modular adjustable hold down clamps secure the electrical module to the rotatable structure and slide along the structure to accommodate different electrical modules that may have different mounting formats. These adjustable hold down clamps benefit from polymer module pins that may be customized to fit any electrical module design and create electrical isolation for sensitive electrical testing. This rotisserie structure is mounted to motors, hand cranks, and/or other such rotational mechanisms to enable multiple rotational orientations and easy access to all electrical module surfaces.