Modular Battery Testing Shelf with Pneumatic Connection
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Solution Overview
Problem
Existing battery testing systems face challenges in safely and efficiently testing high amperage batteries due to issues with cable routing, safety concerns with high amperage connections, and the need for frequent reconfiguration to accommodate different battery types and sizes.
Innovation Solution
The All Test Platform Heavy (ATP Heavy) provides a configurable, scalable, and safe system for high-density battery testing. It features a flexible fixture frame, pneumatic or manual connection systems, and high amperage bus bars with spring-loaded connections, allowing for easy insertion and connection of multiple batteries without external disconnects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple batteries are tested on a single shelf with hard-wired cable connections, then the quantity of batteries tested per chamber is limited, but the system complexity and setup time are reduced
Solution Approach 1:
The system divides the testing platform into multiple independent shelves, each capable of holding and connecting to multiple batteries simultaneously. This segmentation allows parallel testing of numerous batteries without requiring complex cable routing across a single large platform, thereby increasing throughput while managing system complexity through modular organization.
Solution Approach 2:
The shelves are designed with universal connection points and standardized cable routing paths that can accommodate different battery types and configurations. This multi-functionality allows the same shelf structure to serve multiple testing purposes without requiring complex reconfiguration, increasing productivity while maintaining manageable system complexity.
2Ease of operation
If technicians manually connect and disconnect high amperage cables for each battery test, then the ease of operation is maintained, but the safety risks and setup time increase
Solution Approach 1:
The system pre-configures cable connections at the shelf level before batteries are placed. Connection points are prepared and organized in advance, allowing batteries to be connected quickly and safely without requiring technicians to manually route and connect high amperage cables during each testing operation, thereby improving both safety and ease of operation.
Solution Approach 2:
The shelf structure acts as an intermediary between the external power sources and the batteries. It provides standardized connection points and cable management infrastructure that simplifies the connection process while ensuring safe and reliable high amperage connections, reducing both operational complexity and safety risks.
3Manufacturing precision
If the testing system is configured for specific battery types, then the manufacturing precision and testing accuracy are improved, but the adaptability to different battery formats decreases
Solution Approach 1:
The shelves are designed with adjustable and reconfigurable features that allow the connection points and support structures to be dynamically adapted to different battery types and formats. This dynamic design enables the system to maintain precise connections for each specific battery type while simultaneously accommodating a wide variety of battery configurations, resolving the contradiction between precision and adaptability.
Solution Approach 2:
The connection system incorporates universal mounting points and adjustable fixtures that can be configured for different battery types. This multi-functionality allows the same shelf structure to provide precise, optimized connections for various battery formats without requiring dedicated fixtures for each type, thereby maintaining both precision and adaptability.
4Adaptability or versatility
If technicians frequently reconfigure the testing setup for different battery types, then the adaptability is maintained, but the loss of time and productivity decrease
Solution Approach 1:
The system provides pre-configured shelves with standardized connection points and cable routing that are prepared in advance for multiple battery types. This preliminary configuration eliminates the need for time-consuming reconfiguration when switching between battery types, allowing technicians to simply place batteries on the appropriate shelves and begin testing, thereby maintaining adaptability while minimizing time loss.
Solution Approach 2:
The shelves are designed as multi-functional units that can accommodate different battery types without requiring reconfiguration. This universality allows the same shelf structure to serve multiple testing purposes, eliminating setup time while maintaining the ability to test various battery formats, thus resolving the contradiction between adaptability and time efficiency.
Data Source
AI summary
The ATP Heavy allows for specific battery types to be easily inserted on shelving that can be configured depending on the battery type and testing needs. In one embodiment these shelves are then manually or pneumatically controlled to safely engage the battery to a connecting plate for connectivity and full power testing. This allows an operator/test technician to safely change the batteries and begin testing without any requirement to disconnect and reconnect external devices and test equipment. Time savings and testing density are optimized in the platform.