Battery Servicing Station for Automated Defective EV Battery Ejection
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Solution Overview
Problem
Existing methods for transporting and handling defective electric vehicle (EV) batteries are hazardous due to human intervention and lack a holistic testing process for both new and used batteries, posing risks to service stations and operators.
Innovation Solution
A battery servicing system with actuators and a controller for automated battery positioning, testing, and safe ejection of malfunctioning batteries into a container for transportation, using sensors and an off-grid energy storage system for seamless operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional lifting methods with human intervention are used to transport defective EV batteries, then the batteries can be moved to a safe location, but the operators face safety hazards and the process requires manual labor
Solution Approach 1:
The system enables automated self-service transport of defective batteries through a robotic arm that autonomously picks up, transports, and places batteries into containers without human intervention. The controller automatically manages the entire process from detection to safe storage, eliminating the need for operators to physically handle hazardous batteries.
Solution Approach 2:
The patent replaces manual mechanical lifting operations with an automated robotic system. The robotic arm, controlled by a controller, substitutes human operators in performing the mechanical task of moving defective batteries, thereby eliminating safety hazards while maintaining operational efficiency.
2Productivity
If defective EV batteries are transported manually to dedicated service stations, then the batteries can be disposed of, but the transportation process is time-consuming and labor-intensive
Solution Approach 1:
The system merges the testing, identification, and transport functions into a single integrated automated workflow. The controller coordinates the robotic arm to immediately transport defective batteries upon identification, eliminating separate manual handling steps and reducing overall process time while increasing productivity.
Solution Approach 2:
The automated system enables continuous operation without interruption by the robotic arm continuously monitoring, picking up, and transporting defective batteries as they are identified during testing, maintaining an uninterrupted workflow that maximizes productivity and minimizes idle time.
3Reliability
If a holistic testing process is implemented for both new and used EV batteries, then comprehensive quality assurance is achieved, but the system complexity increases
Solution Approach 1:
The testing system is designed with universal multi-functionality to handle both new and used EV batteries using the same testing protocols and procedures. The controller is programmed with comprehensive testing algorithms that adapt to different battery types and conditions, achieving reliable quality assurance without requiring separate complex systems for different battery categories.
Data Source
AI summary
A battery servicing system for use in a battery servicing station, includes a plurality of actuators and a controller configured to control the plurality of actuators to position a battery being tested on a lid that is configured as a test plate on a workstation in the battery servicing station. The controller is configured to test the battery based on a predefined set of reference parameters and automatically eject the battery from the battery servicing station when the battery is determined to be malfunctioning. The controller is configured to drop a container part onto the malfunctioning battery such that the lid and the container part are gaged along with the malfunctioning battery and transport away from the battery servicing station. The battery servicing system improves the safety of disposal of a malfunctioned battery by enabling an efficient and fail-safe automatic ejection of the malfunctioned battery outside the battery servicing station.