Modular Battery Cover Assembly for Scalable EV Battery Protection
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Solution Overview
Problem
The underground mining environment poses challenges for battery systems in electric vehicles due to dust and darkness, requiring a cover assembly that is scalable and adjustable for different battery configurations while ensuring easy access and protection.
Innovation Solution
A modular cover system comprising interconnectable segments with protruding portions and slots allows for customizable sizing and configuration, providing a secure and continuous enclosure for battery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed cover assembly is used for battery systems, then the structure is simple and manufacturing is easy, but the cover cannot accommodate different battery configurations and sizes
Solution Approach 1:
The cover assembly is divided into multiple modular cover segments that can be independently configured and assembled. Each segment can be selectively attached to accommodate different battery module arrangements, allowing the same set of segments to serve multiple battery configurations without requiring a completely different cover design for each scenario.
Solution Approach 2:
The modular cover segments are designed with universal attachment features that allow them to be used in various positions and combinations. The segments can be assembled in different configurations to match various battery module layouts, making a single set of cover segments applicable to multiple battery system configurations rather than requiring dedicated covers for each configuration.
2Reliability
If a customized cover is designed for each battery configuration, then the fit and protection are optimal, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
Instead of manufacturing complete custom covers for each battery configuration, the system segments the cover into standardized modules. These segments are manufactured using the same processes regardless of the final configuration needed, simplifying manufacturing. The customization is achieved through assembly rather than through complex manufacturing processes.
Solution Approach 2:
The cover segments are pre-manufactured with standardized attachment features and protection characteristics. Rather than customizing the entire cover for each application, the segments are prepared in advance with universal interfaces that enable flexible assembly into configuration-specific arrangements, reducing both manufacturing complexity and assembly time.
3Adaptability or versatility
If a modular cover system with multiple segments is used, then adaptability to different configurations is improved, but the assembly complexity increases
Solution Approach 1:
The cover is segmented into modular units with standardized interfaces. Each segment is designed to attach to others through consistent connection mechanisms, reducing the cognitive load required for assembly. The segmentation allows workers to assemble the cover in a systematic, step-by-step manner rather than dealing with a single complex custom-fitted piece.
Solution Approach 2:
The universal attachment features across all cover segments mean that the same connection and alignment procedures apply regardless of which segments are being assembled or in what configuration. This consistency simplifies the assembly process and reduces training requirements, as workers learn one set of assembly procedures that apply to all configurations.
4Object-affected harmful factors
If protective enclosure is provided for battery modules, then environmental protection is improved, but access for assembly and disassembly becomes more difficult
Solution Approach 1:
The protective cover is segmented into removable modules rather than being a single sealed enclosure. This allows individual segments to be detached for access to specific battery modules while maintaining protection for the remaining enclosed sections. The segmentation enables localized access without requiring complete disassembly of the entire protective cover.
Solution Approach 2:
The cover system transitions from a static, fixed enclosure to a dynamic, reconfigurable structure. The modular segments can be attached and detached as needed, allowing the protective enclosure to adapt its configuration based on maintenance or assembly requirements. This dynamic capability enables the cover to provide both comprehensive protection and easy access depending on the operational state.
Data Source
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AI summary
A modular cover for a battery system and a method for assembling the modular cover are disclosed. The apparatus can include a first modular segment and a second modular segment that are interconnected. The modular cover can be expanded in size for use with different types of battery systems and housings.