Rail-Mounted Battery Carrier Tray for Tool-Free Service Access
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Solution Overview
Problem
Battery systems in harsh environments require complex and time-consuming maintenance due to the need for manual removal of electrical cables and coolant lines, as well as depressurization of cooling systems during servicing.
Innovation Solution
A battery group design featuring a carrier tray with an upper rail mount and output terminals positioned on the rear face, allowing for automatic connection and disconnection of electrical and cooling systems when installed or removed, simplifying maintenance by enabling sliding engagement with a mounting rail and cabinet enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual removal of electrical cables and coolant lines is used for battery servicing, then connection reliability is maintained, but maintenance time and operational complexity increase significantly
Solution Approach 1:
The battery system is divided into modular battery groups that can be independently serviced. Each battery group contains integrated electrical and cooling connections that move together as a unit, allowing partial servicing without disconnecting individual cables or coolant lines from the entire system.
Solution Approach 2:
The electrical cables and coolant lines are nested within the battery group structure itself, with connections integrated into the carrier tray assembly. This nested arrangement allows the battery group to be removed and serviced as a complete unit while maintaining all connections intact.
2Object-affected harmful factors
If cooling systems are depressurized during servicing, then safety is improved, but service complexity and time requirements increase
Solution Approach 1:
The cooling system is segmented into individual battery group circuits rather than a single pressurized system. Each battery group has its own cooling loop that can be isolated and serviced independently without affecting or depressurizing the entire cooling system.
Solution Approach 2:
The battery group is extracted as a complete serviceable unit with its cooling connections still attached and pressurized. The cooling system remains intact and pressurized in the cabinet while the battery group is removed for servicing, eliminating the need to depressurize the cooling system.
3Ease of operation
If electrical cables and coolant lines are manually disconnected for battery access, then component accessibility is improved, but operational complexity and time requirements increase
Solution Approach 1:
The battery system is organized into discrete battery groups that can be accessed and serviced independently. Each group maintains its complete set of electrical and cooling connections, allowing technicians to work on individual modules without managing disconnected cables throughout the system.
Solution Approach 2:
The electrical cables, coolant lines, and battery components are merged into an integrated battery group assembly. This combination allows all connections to move together as one unit, providing easy access to battery components while eliminating the complexity of manually managing separate cables and lines.
Data Source
AI summary
A battery group includes a carrier tray, battery module, and set of output terminals. The carrier tray includes an upper rail mount adapted to be received by a mounting bracket. The battery module is coupled to the carrier tray. The output terminals are operatively coupled to terminals of the battery module, the output terminals positioned on a rear face of the carrier tray. The carrier tray and battery module are adapted to be slidingly received by a cabinet or other enclosure such that the output terminals are engaged to an electrical system of the cabinet or other enclosure by sliding the battery group fully into the cabinet or other enclosure.