EV Battery Rack Assembly for Modular Charging and Service Access
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Solution Overview
Problem
Current electric vehicle battery systems are complex to service and charge, requiring expensive and time-consuming procedures, making routine inspection and maintenance impractical due to the need for specialized equipment and the fixed nature of battery housings.
Innovation Solution
A system and method for servicing, charging, and monitoring electric vehicle battery modules using an electro-mechanical rack assembly with multiple compartments and integrated charging and control systems, allowing for swappable battery modules and remote management through a networked communication architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are mounted in a fixed housing within the vehicle, then the battery system is structurally stable and protected, but the battery becomes inaccessible for routine inspection and servicing
Solution Approach 1:
The battery system is divided into modular battery packs that can be independently removed and serviced. Each battery pack is a self-contained unit that can be extracted from the vehicle without disassembling the entire battery housing, enabling routine inspection and maintenance while maintaining system stability during operation.
Solution Approach 2:
Individual battery packs are designed to be extractable from the vehicle's battery housing. This extraction capability allows batteries to be removed for servicing, charging, or replacement without affecting the structural integrity of the remaining battery system or requiring complex disassembly procedures.
2Ease of repair
If traditional battery removal procedures are used, then complete battery units can be extracted, but the process requires special heavy equipment and is time-consuming
Solution Approach 1:
The battery system is segmented into smaller, manageable battery packs that can be handled with standard equipment rather than heavy machinery. This segmentation reduces the time and equipment requirements for battery removal and servicing operations.
Solution Approach 2:
The battery pack design incorporates quick-release mechanisms and standardized interfaces that enable rapid installation and removal. This dynamic design allows battery packs to be quickly exchanged during servicing operations, significantly reducing the time required compared to traditional fixed mounting systems.
3Device complexity
If batteries are treated as non-accessible components, then the vehicle structure remains simple, but servicing sub-assemblies becomes impossible
Solution Approach 1:
The battery system is organized into modular packs with standardized interfaces, allowing individual sub-assemblies to be accessed and serviced independently. This modular structure maintains relative simplicity in the vehicle's overall battery system while enabling granular access to specific battery components for maintenance and repair.
4Reliability
If expensive specialized procedures are used for battery servicing, then battery safety is maintained, but maintenance costs increase
Solution Approach 1:
By segmenting the battery system into standardized modular packs with uniform interfaces and safety features, the invention enables routine servicing to be performed with standard equipment and procedures rather than expensive specialized systems. This reduces maintenance costs while maintaining safety through consistent design across all battery packs.
Solution Approach 2:
The battery pack design incorporates standardized electrical and mechanical parameters that allow for consistent, repeatable servicing procedures. This standardization enables routine maintenance to be performed safely with conventional equipment, eliminating the need for expensive specialized servicing procedures while maintaining battery safety through controlled, predictable operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and accessible servicing, charging, and monitoring of electric vehicle battery modules, optimizing battery life and reducing maintenance costs by allowing for easy replacement and management of battery modules without the need for specialized equipment.
Implementation Method 1
each charger provides direct current (DC) electrical power to charge one or more battery modules disposed in the corresponding battery rack
Data Source
AI summary
A rack-based system for charging, monitoring and maintaining a plurality of batteries is described. The system includes mechanical and electrical frameworks for achieving the foregoing as well as a communication framework for exchanging necessary data for achieving the same. A state machine and associated controllers and control signals are additionally provided for operating the present system.