Rack Tray Structure for Easier Battery Cell Loading and Replacement
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Solution Overview
Problem
Existing battery pack and energy storage systems face complexity and high costs in installing or replacing battery cells due to their stacked structure.
Innovation Solution
A rack assembly with a rack frame and tray system that allows easy loading and replacement of battery cells, featuring an elongated tray with upward extensions and couplers for secure positioning and bus bar connections, facilitating efficient cell stacking and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are stacked and coupled to bus bar in existing structure, then battery pack can be assembled, but the process of installing or replacing battery cells becomes very complicated and cost increases
Solution Approach 1:
The battery pack is divided into modular units with individual trays for each battery cell. Each tray is a separate, interchangeable component that can be independently loaded, removed, or replaced without affecting other cells. This segmentation transforms the complex stacked structure into simple modular units, dramatically easing the manufacturing and maintenance processes.
Solution Approach 2:
The tray design incorporates movable and adjustable elements such as adjustable support plates and flexible positioning mechanisms that allow easy insertion and removal of battery cells. The dynamic structure enables the tray to adapt to different cell positions and orientations, simplifying the loading and replacement operations compared to rigid fixed structures.
2Productivity
If battery cells are stacked in existing structure, then battery pack can be assembled, but the process of replacing battery cells becomes complicated and time-consuming
Solution Approach 1:
The trays are pre-assembled with all necessary support structures, positioning elements, and electrical connections before being installed in the battery pack. This preliminary preparation allows battery cells to be quickly swapped by simply removing and replacing entire trays, eliminating the need for time-consuming on-site assembly and connection work during replacement operations.
Solution Approach 2:
The tray structure employs nested components where support plates, positioning elements, and electrical contacts are integrated within the tray body. This nested design allows the entire assembly to be compact yet fully functional, enabling rapid replacement by treating each tray as a single integrated unit rather than multiple separate components.
3Adaptability or versatility
If existing battery rack structure is used, then battery cells can be held, but the structure does not facilitate easy replacement and incurs high costs
Solution Approach 1:
The tray design serves multiple functions simultaneously: it provides mechanical support for the battery cell, establishes electrical connections through integrated bus bar contacts, enables positioning and alignment, and facilitates easy removal and replacement. This multi-functional universal design eliminates the need for specialized tools or procedures for different operations, reducing both manufacturing complexity and replacement costs.
Data Source
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AI summary
A rack assembly (300) is disclosed. The rack assembly (300) comprises a rack frame (310) including a rack scaffold (311) and a rack deck (312) coupled to the rack scaffold (311), and a tray (320) coupled to the rack deck (312). The rack deck (312) is elongated in a front-rear direction. The tray (320) includes a tray body (321) facing the rack deck (312) and positioned above the rack deck (312), and a tray wall (322) extending upward from an edge of the tray body (321). The edge of the tray body (321) extends rearward from a front end of the tray body (321) and leads to a rear end of the tray body (321).