Distributed Battery Testing System Parallel Stations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional battery functional testing systems are time-intensive, prone to system failure, and inefficient due to their sequential and non-continuous operations, which can lead to delays and increased downtime.
Innovation Solution
A distributed system of automation, charging, and discharging devices in a series and parallel configuration, with a transport system to facilitate simultaneous and sequential testing, charging, and discharging operations, optimizing device utilization and reducing cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sequential testing operations are used, then system simplicity is maintained, but productivity and throughput are reduced
Solution Approach 1:
The testing system is divided into multiple independent testing stations (first testing station, second testing station, etc.) that can operate simultaneously on different battery packs. Each station performs specific testing functions, allowing parallel processing and significantly increasing overall throughput while maintaining manageable complexity at each individual station.
Solution Approach 2:
Multiple testing stations are combined into a coordinated system with centralized control. The control system synchronizes operations across stations, manages battery pack flow, and aggregates test results, enabling the system to achieve high productivity through parallel operations while maintaining system-wide coordination.
2Productivity
If continuous testing operations are implemented, then productivity improves, but system reliability decreases due to increased failure risk
Solution Approach 1:
By segmenting the continuous testing process into discrete stations, the system isolates potential failure points. If one station experiences a failure, other stations can continue operating or enter safe mode independently, preventing complete system shutdown and maintaining partial productivity during fault conditions.
Solution Approach 2:
The control system continuously monitors the status of each testing station and provides real-time feedback. When a fault is detected, the control system can adjust operations, redirect battery packs, or initiate corrective actions to maintain system reliability while minimizing impact on overall productivity.
3Loss of time
If multiple testing stations operate in parallel, then cycle time is reduced, but device complexity increases
Solution Approach 1:
A centralized control system acts as an intermediary between parallel testing stations, coordinating their operations. The control system manages battery pack routing, synchronizes test sequences, and harmonizes operations across stations, enabling parallel processing to reduce cycle time while the intermediary handles the coordination complexity centrally.
4Loss of time
If traditional sequential operations are used, then ease of operation is maintained, but loss of time increases
Solution Approach 1:
The testing system is designed to operate autonomously with automated battery pack handling, station coordination, and test execution. Once initiated, the system self-manages the parallel testing operations across multiple stations without requiring continuous manual intervention, thereby reducing testing duration while maintaining ease of operation through automation.
Data Source
AI summary
A system may be configured for distributed functional testing of one or more batteries. The system may include a charging station, a discharging station, and an automation station in a distributed arrangement with respect to each other, having respective automation and communication devices, and being in communication with each other to separately charge, discharge, and test the one or more batteries. The automation station may be arranged in at least one of a series configuration and a parallel configuration with respect to at least one of the charging and discharging stations.