Parallel Plate Battery Thickness Measurement in Thermal Chambers
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Solution Overview
Problem
Existing battery thickness measurement tools have limitations such as low resolution, poor thermal tolerance, and a large form factor, which result in inaccurate measurements and the need to remove batteries from thermal chambers for manual measurement, leading to reduced accuracy and increased operator time.
Innovation Solution
A parallel plate measurement system with a high thermal tolerance, small form factor, and high resolution, allowing for accurate battery thickness measurements within a thermal chamber without removing the battery, using a dynamic top plate and counterweight system with adjustable force and a linear encoder for precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used, then operator flexibility is maintained, but measurement accuracy decreases and operator time increases
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated measurement system that includes a measurement tool positioned between the plates. This tool automatically records thickness data without requiring operator intervention, thereby increasing both measurement accuracy and operational speed.
Solution Approach 2:
The measurement system is designed to autonomously perform measurements as batteries pass through the apparatus. The system self-regulates the measurement process, eliminating the need for manual operation while maintaining high measurement accuracy and reducing operator time requirements.
2Measurement precision
If batteries are removed from thermal chambers for measurement, then measurement can be performed, but measurement accuracy decreases due to temperature changes
Solution Approach 1:
The patent introduces a thermal chamber as an intermediary environment that maintains controlled temperature conditions during measurement. The measurement apparatus is positioned within or connected to the thermal chamber, allowing batteries to be measured in-situ without temperature changes that would affect accuracy.
3Reliability
If existing measurement tools are used, then simplicity is maintained, but thermal tolerance and resolution are insufficient
Solution Approach 1:
The patent modifies the operational parameters of the measurement system by implementing temperature control mechanisms and high-resolution measurement capabilities. These parameter changes enable the system to maintain reliability under thermal conditions while achieving the required measurement precision through controlled environmental parameters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables high-frequency, high-fidelity battery thickness measurements that correlate well with charge cycle, age, and temperature, improving trend analysis and prediction accuracy, while reducing operator time and maintaining measurement accuracy within a thermal environment.
Implementation Method 1
a pivot arm with a first end flexibly coupled to the dynamic top plate and a second end flexibly coupled to a counterweight. The pivot arm is adapted to rotate about a pivot bearing to apply directionally-opposing forces to the counterweight and dynamic top plate.
Implementation Method 2
a counterweight adapted to slide linearly along a second rail bearing in the direction perpendicular to the stationary bottom plate
Data Source
AI summary
A parallel plate measurement apparatus for measuring battery thickness includes a stationary bottom plate and a dynamic top plate fixed in a parallel orientation relative to the stationary bottom plate. The dynamic top plate is adapted to slide linearly along a first rail bearing in a direction perpendicular to the stationary bottom plate, and the system further includes a counterweight adapted to slide linearly along a second rail bearing in the direction perpendicular to the stationary bottom plate. Additionally, the parallel plate measurement apparatus further includes a pivot arm with a first end flexibly coupled to the dynamic top plate and a second end flexibly coupled to a counterweight. The pivot arm is adapted to rotate about a pivot bearing to apply directionally-opposing forces to the counterweight and dynamic top plate that, in turn, impart movement on the counterweight and the dynamic top plate that is constrained by the first rail bearing and the second rail bearing. The system still further includes a linear encoder adapted to measure a separation between the stationary bottom plate and the dynamic top plate.