De-celling Battery Modules for Telecom Site Installation
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Solution Overview
Problem
The installation and maintenance of batteries in cell sites are labor-intensive and time-consuming due to their weight and the high theft rates, with a need for efficient recycling and auditing processes amidst increasing environmental and health regulations.
Innovation Solution
A method involving de-celling batteries into individual modules for easier handling and installation, using a battery installation apparatus with omnidirectional wheels and security screws for theft deterrence, and implementing a recycling system with mobile device tracking and cloud-based verification for compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batteries are installed as complete modules at cell sites, then installation speed is improved, but labor intensity increases due to severe weight
Solution Approach 1:
The battery system is divided into multiple individual battery cells that can be handled separately. Each cell weighs significantly less than a complete battery module, enabling workers to transport and install them individually without excessive physical strain, while still achieving complete battery system installation at the cell site.
Solution Approach 2:
A battery installation apparatus serves as an intermediary device that facilitates the transfer and positioning of individual battery cells. The apparatus includes features such as omnidirectional wheels for mobile positioning and mechanical assistance for lifting and securing cells, reducing the direct physical burden on workers.
2Device complexity
If complete battery modules are transported to cell sites, then installation complexity is reduced, but theft risk increases due to high value and ease of removal
Solution Approach 1:
By segmenting the battery system into individual cells, the value and portability of each transportable unit are significantly reduced. Individual cells are less attractive to thieves compared to complete battery modules, and their distributed installation throughout the battery system makes theft more difficult and less profitable.
Solution Approach 2:
The battery cells are pre-assembled into the battery housing structure at a centralized location before transport. This preliminary assembly of the housing framework (without the valuable battery cells) allows for secure installation at the cell site, and the cells are then individually inserted and secured, making the complete system harder to steal in its installed state.
3Ease of operation
If individual battery cells are handled and installed separately, then labor requirements are reduced, but installation time increases due to multiple handling steps
Solution Approach 1:
The battery installation apparatus acts as a time-saving intermediary by providing mechanical assistance for lifting, positioning, and securing individual battery cells. The apparatus includes features such as movable shelves, lifting mechanisms, and securing systems that automate or semi-automate the installation process, reducing the time required for each individual cell installation despite the increased number of handling steps.
Solution Approach 2:
The installation apparatus is designed to operate at the same level as the battery housing, eliminating the need for repeated lifting and lowering of cells between different height levels. The apparatus can be positioned and adjusted to match the installation plane, making the handling of individual cells more efficient and time-effective.
Data Source
AI summary
A method of installing batteries in a telecommunications site includes obtaining a battery in a module with a plurality of cells in the module at a staging location; de-celling the battery to remove the plurality of cells from the module; handling the plurality of cells individually at the staging location; transporting the plurality of cells individually to the telecommunications site; and reassembling the battery by placing the plurality of cells back in the module and installing the module at the telecommunications site.