Rechargeable Battery Design-Build-Test Management at Scale
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Solution Overview
Problem
Existing solutions lack a system for inputting specifications and test conditions, staging the build process, reserving test channels, notifying technicians, and tracking status, measurements, and observations during the design, build, and teardown of rechargeable batteries, particularly for large volumes.
Innovation Solution
A cloud-based software platform integrates design, build, and test management, allowing administrators to configure test infrastructure and item components, designers to specify items and conditions, builders to reserve channels, and testers to track metadata throughout the process, using functionalities like notification and project management tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional battery testing systems with single or double digit channels are used, then testing capability for small volume is adequate, but scalability to large volume testing is limited
Solution Approach 1:
The system divides the large-scale testing infrastructure into modular battery cyclers, each with multiple channels. The software platform segments the management of thousands of channels across multiple devices, allowing scalable expansion from small to large volume testing without creating a monolithic complex system.
Solution Approach 2:
The software platform provides universal functionality to manage diverse battery cycler configurations and test protocols across multiple devices simultaneously. A single platform can control anything from a few to thousands of channels, adapting to different testing volumes and requirements without requiring separate specialized systems.
2Productivity
If manual tracking and management methods are used, then simplicity is maintained, but efficiency and error reduction in large volume testing are insufficient
Solution Approach 1:
The system implements automated self-service capabilities including automatic channel allocation, test result collection, and data tracking. The software platform autonomously manages the complex coordination of multiple battery cyclers, channels, and test protocols without requiring manual intervention for each testing operation.
Solution Approach 2:
The system incorporates continuous feedback loops that automatically collect test results from battery cyclers, track channel utilization, and provide real-time status information. This automated feedback mechanism enables efficient decision-making and system optimization without manual monitoring.
3Reliability
If resource allocation is done without staging, then responsiveness is improved, but resource readiness and coordination in large volume testing are compromised
Solution Approach 1:
The software platform performs preliminary actions by pre-allocating and staging test channels based on upcoming test schedules. Resources are prepared and coordinated in advance, ensuring readiness before testing begins while automating the coordination process to minimize time loss.
Data Source
AI summary
Detailed herein are systems and methods for large volume design, building, and testing, particularly suited for rechargeable batteries intended for long duration energy storage. A specific item, such as a battery cell, may be designed through input and selection of various components and configurations, along with desired test protocols and configurations. A build team is notified of the new item, and confirms material and resources are ready to build the item. A specific channel is reserved or committed for the test. Test data, along with specifics and any errors or conditions encountered from specification through teardown, is tracked.