Modular Battery Case Assembly for Vehicle-Specific Pack Customization
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Solution Overview
Problem
Customization of battery devices for different work vehicles imposes a heavy burden on designers and manufacturers, leading to increased costs, reduced economies of scale, and challenges in maintenance and inspection due to varying specifications.
Innovation Solution
A battery case design comprising multiple case members that can be stacked and coupled in various configurations to accommodate battery modules, allowing easy adjustment of size and specifications, including the addition of heating or cooling functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery devices are customized for each work vehicle to meet different specifications, then the battery device can be adapted to specific vehicle requirements, but the design burden and manufacturing cost increase significantly
Solution Approach 1:
The battery case is divided into multiple stackable case members (first case member, second case member, etc.) that can be independently manufactured and then assembled. Each case member has standardized coupling portions that enable modular assembly, allowing different configurations to be created from the same basic components without redesigning the entire battery device.
Solution Approach 2:
The case members are designed with universal coupling portions (first coupling portions and second coupling portions) that can be used across different battery device configurations. The same case member design can serve multiple vehicles with different specifications by simply changing the number and arrangement of stacked case members, eliminating the need for vehicle-specific custom designs.
2Adaptability or versatility
If battery devices are customized for each work vehicle, then specific vehicle requirements are met, but economies of scale are reduced and manufacturing costs increase
Solution Approach 1:
By segmenting the battery case into standardized case members, the manufacturer can produce large quantities of identical modular components through mass production. These pre-fabricated modules can then be assembled into different battery device configurations as needed, achieving both economies of scale and customization.
Solution Approach 2:
The battery modules are accommodated within the stacked case members in a nested arrangement, where multiple identical case members contain and organize battery modules. This nesting approach allows standardized components to be combined in varying quantities to meet different capacity requirements without requiring custom manufacturing for each specification.
3Adaptability or versatility
If battery devices have different specifications for different work vehicles, then vehicle-specific performance is achieved, but maintenance and inspection become more difficult
Solution Approach 1:
The segmented case member design allows maintenance personnel to access and service individual battery modules or case members independently. If a problem is identified in one module, only that specific module needs to be removed and replaced, rather than servicing the entire battery device, significantly improving maintenance efficiency across all vehicle types.
Solution Approach 2:
Since all case members use the same standardized coupling portions and internal structures, maintenance procedures and replacement parts are universal across all battery device configurations. A technician trained on one configuration can service any configuration, and replacement case members are interchangeable, simplifying the maintenance ecosystem.
4Ease of manufacture
If a fixed battery case design is used, then manufacturing is simplified, but the ability to adapt to different work vehicle specifications is limited
Solution Approach 1:
The battery case design transitions from a fixed, monolithic structure to a dynamic, reconfigurable system. The standardized coupling portions enable case members to be stacked in different numbers and arrangements, allowing the battery device capacity and configuration to be dynamically adjusted to match different vehicle requirements while maintaining the same basic component design.
Data Source
AI summary
A battery case of a battery device includes a plurality of case members stacked in a first direction, and an accommodation space. The accommodation space is capable of accommodating a battery module between the case members adjacent to each other in the first direction. The case member on one side further has first coupling portions. The first coupling portions are disposed on both end sides in a second direction intersecting the first direction of the plate portion of the case member on the one side. The case member on the other side further has second coupling portions. The second coupling portions are disposed on both end sides in the second direction of the case member on the other side and are coupled to the first coupling portions.