Modular Battery Belt System for Rapid Cell Swapping
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Solution Overview
Problem
Current rechargeable battery systems face issues with thermal regulation, uneven charge distribution, limited versatility, and rapid charging/discharging leading to overheating and potential damage, as well as the inability to rapidly replace defective cells, which affects the efficiency and longevity of battery packs in applications like electric vehicles.
Innovation Solution
A flexible serpentine belt arrangement for linking batteries together, allowing for easy handling and selective replacement of individual cells, along with a conduit system for electrical connection and actuator-driven battery swapping, enabling rapid change-out and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If fast charging or discharging is performed to meet user demand, then power delivery speed is improved, but thermal regulation deteriorates causing overheating of battery cells and energy interface
Solution Approach 1:
The battery array is divided into multiple independently replaceable battery packs, each containing one or more cells. This segmentation allows individual packs to be managed separately, enabling selective replacement of overheated or defective cells without affecting the entire array, thus facilitating faster charging/discharging cycles while maintaining thermal safety.
Solution Approach 2:
The system implements dynamic battery pack replacement capability, allowing batteries to be rapidly swapped out and replaced based on real-time thermal and charge level conditions. This dynamic approach enables the system to respond to thermal regulation needs by replacing overheated packs, thereby supporting fast charging/discharging operations while preventing thermal damage.
2Stability of the object's composition
If complete discharge cycles are performed to condition the whole array, then charge level uniformity is improved, but battery life deteriorates due to increased wear
Solution Approach 1:
Defective or low-charge battery packs are extracted from the array and replaced with fully charged packs. This extraction approach allows individual problematic cells to be removed and conditioned separately, avoiding the need for complete discharge cycles of the entire array. The replaced packs can be recharged and reused, extending overall system life while maintaining charge uniformity.
Solution Approach 2:
The system enables discarding of depleted or defective battery packs and recovering them through separate charging cycles. Instead of discharging the entire array to condition it, individual packs are cycled independently, recovered when charged, and returned to service. This extends battery life while maintaining array-wide charge uniformity.
3Temperature
If traditional battery pack replacement is used, then thermal management is improved, but productivity deteriorates due to lengthy charging cycles
Solution Approach 1:
The battery system is segmented into modular packs that can be independently handled and replaced. This segmentation enables rapid exchange of individual packs without waiting for complete charging cycles, as depleted packs can be quickly swapped out and replaced with charged ones, thereby improving productivity while maintaining thermal management through selective replacement of hot packs.
Solution Approach 2:
Battery packs are pre-charged in advance and held in ready状态 for immediate replacement. This preliminary action allows depleted or overheated packs to be rapidly exchanged with fully charged ones, eliminating lengthy on-site charging waits and significantly improving productivity while maintaining effective thermal management through continuous availability of cool, charged packs.
4Adaptability or versatility
If battery packs are designed with different specifications to meet individual needs, then adaptability is improved, but device complexity deteriorates due to incompatibility
Solution Approach 1:
The system employs universal mechanical and electrical interfaces across all battery packs, allowing packs of different capacities and chemistries to be interchangeably mounted in the same array configuration. This universality enables adaptability to different power needs through selective pack selection while maintaining system compatibility through standardized connection protocols and mounting mechanisms.
Data Source
AI summary
In one embodiment, a system for deploying batteries, for example in an electric vehicle, includes a battery belt for mechanically linking multiple batteries together, a conduit having one or more operational zones each with an output, the operational zones each establishing an electrical connection between the output and batteries in the operational zone, and an actuator for selectively moving batteries into and out of the operational zones. Resting zones may also be provided. The batteries can be connected in series or in parallel and can be individually removed and replaced by an exchanger.