Servo Cell Puller for Precise Vertical Battery Extraction
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Solution Overview
Problem
Existing methods for removing battery cells often cause damage and spillage due to non-vertical extraction, lack of repeatability, and unpredictable production rates, especially when dealing with swollen cells.
Innovation Solution
A powered battery cell puller system equipped with a servo motor actuated screw or hydraulic/pneumatic cylinder, featuring a 3-axis positional gantry and an end effector with an electromagnet or double half nut to ensure vertical and controlled cell removal, preventing damage and shorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual T-Bar pulling or wooden lever methods are used, then device complexity is reduced, but cell extraction precision and reliability deteriorate due to non-vertical movement and damage
Solution Approach 1:
The patent replaces manual mechanical operations (hand-pulling T-Bar, wooden lever) with an automated servo-motor driven ball screw mechanism. This substitution enables precise vertical movement control through electronic control while maintaining mechanical reliability, resolving the contradiction between device simplicity and extraction precision.
Solution Approach 2:
The patent changes the control parameter from manual force application to automated servo-motor controlled linear displacement. The ball screw mechanism converts rotational motion to precise linear motion, allowing controlled extraction speed and position, thereby achieving vertical precision extraction while managing device complexity through standardized components.
2Productivity
If impulse force is applied to dislodge swollen cells, then extraction speed increases, but harmful factors increase due to deflection, torque, and potential spillage
Solution Approach 1:
The patent replaces impulsive force application with continuous, controlled linear motion through the servo-motor and ball screw mechanism. The cell is extracted steadily at controlled speed without sudden jerks or impulses, eliminating deflection and torque while maintaining extraction productivity through automated continuous operation.
Solution Approach 2:
The patent introduces a ball screw mechanism as an intermediary between the servo-motor and the cell extraction process. This intermediary converts rotational motor motion into precise linear motion, providing smooth, controlled force application that prevents cell damage and electrolyte spillage while maintaining extraction speed.
3Ease of operation
If manual pulling methods are used, then ease of operation is improved, but reliability deteriorates due to lack of repeatability and unpredictable production rates
Solution Approach 1:
The patent implements automated servo-motor control that self-regulates the extraction process according to programmed parameters. The system automatically positions, extracts, and returns the cell without manual intervention, ensuring repeatable operation and predictable production rates while maintaining ease of operation through simple control interface.
Solution Approach 2:
The patent incorporates control systems with feedback mechanisms that monitor and adjust extraction parameters in real-time. The servo-motor receives feedback on position and motion, automatically correcting deviations to ensure repeatable vertical extraction, thereby improving reliability while maintaining operational simplicity through automated control.
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
Ensures strong, predictable vertical movement for safe cell extraction with reduced deflection and torque stress, enhancing production efficiency and repeatability.
Implementation Method 1
The end effector can include an electromagnet that when energized attaches to the cell
Implementation Method 2
an electrically powered servo motor actuated screw
Implementation Method 3
a servo motor coupled to a jack screw supported by a least one ball screw
Data Source
AI summary
A powered battery cell puller system designed to assist in the removal of individual cells from a battery is disclosed. In one embodiment, the powered battery cell puller system is equipped with an electrically powered servo motor actuated jack screw or a pneumatically or hydraulically powered cylinder, and an end effector that couples to an accessible portion of an individual cell. The end effector can include an electromagnet that when energized attaches to the cell or a double half nut that mechanically connects to studs of the cell while maintaining electrical isolation of the studs to prevent shorting the cell. The resulting strong, predictable vertical movement is advantageous for removing cells from a battery with less deflection, torque stress or damage. Initially developed to aid in removal of cells from batteries, its design versatility extends to various other applications.