Battery Rack Tray Assembly for Easier Cell Replacement
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Solution Overview
Problem
Existing battery pack and energy storage systems face complexity and high costs due to the intricate process of installing or replacing multiple battery cells, which are stacked and coupled to bus bars on a rack.
Innovation Solution
A rack assembly with a rack frame and tray system that allows for easy loading and replacement of battery cells, featuring a rack scaffold, rack deck, and trays with elongated designs and couplers, enabling efficient stacking and bus bar connection in a front-rear direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are stacked and coupled to bus bars on a rack in the existing structure, then the battery pack can be assembled, but the installation and replacement process becomes very complicated and costly
Solution Approach 1:
The battery pack is divided into modular units: a rack assembly (containing the rack frame and multiple decks), tray assemblies (each holding multiple battery cells), and bus bar assemblies. This segmentation allows independent assembly and replacement of trays without affecting the entire battery pack, significantly simplifying installation and maintenance processes
Solution Approach 2:
The rack decks serve as intermediary components between the rack frame and the tray assemblies. The trays are coupled to the decks, which provide a standardized interface for mounting. This intermediary structure enables easy attachment and detachment of trays, reducing the complexity of battery cell installation and replacement
2Reliability
If multiple battery cells are stacked and coupled to bus bars, then the battery pack achieves required capacity, but the replacement cost and complexity increase significantly
Solution Approach 1:
By dividing the battery cells into groups mounted on separate tray assemblies, the system enables targeted replacement of only the faulty cells or trays rather than requiring replacement of the entire battery pack. This modular approach maintains reliability while significantly reducing repair complexity and cost
Solution Approach 2:
The tray assemblies are designed to be dynamically removable and reattachable to the rack decks, allowing flexible maintenance operations. This dynamic coupling mechanism enables quick replacement of battery cells without complex disassembly procedures, improving ease of repair while maintaining system functionality
Data Source
AI summary
A rack assembly is disclosed. The rack assembly comprises a rack frame including a rack scaffold and a rack deck coupled to the rack scaffold, and a tray coupled to the rack deck. The rack deck is elongated in a front-rear direction. The tray includes a tray body facing the rack deck and positioned above the rack deck, and a tray wall extending upward from an edge of the tray body. The edge of the tray body extends rearward from a front end of the tray body and leads to a rear end of the tray body.