📄 Instruction for Shortening Rails in Charging Module Slots by Swobbee Station
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Instruction for Shortening Rails in Charging Module Slots by Swobbee Station

Purpose:

To reduce the risk of damaging the battery housing caused by hitting the end of the rail too hard. All rails must be shortened by approx. 3 mm (0.12 in).

1. Preparation

  • Power off and secure the charging station.

  • Make sure the slot is empty (no batteries or other components inside).

  • Prepare the following tools:

    • Dremel with grinding disc 

    • fine-grit sandpaper 

    • measuring tape/ruler to check dimensions,

    • personal protective equipment (safety glasses, gloves).

2. Rail Rework

  • Locate the ends of all rails in the slots.

  • Using the Dremel, shorten all rails by approx. 3 mm.

  • Smooth out the edges with sandpaper to remove sharp corners and prevent damage.

  • Carefully remove all grinding debris and metal shavings, as they may cause scratches or damage to the battery surface.

  • Photos are for reference only – they show what the rail looks like before and after rework.

3. Dimension Check

  • Verify the clearance between the shortened rail and the housing.

  • There should be approx. 3 mm of free space, which prevents the battery from hitting the rail end.

  • Photos are for reference only – they show how the clearance is measured.
     

  • Video demonstrates a proper verification after rail rework.

4. Functional Verification

  • Insert a test battery into the slot.

  • Ensure that the battery housing does not come into contact with the rail end.

  • Compare the reworked slot with an original slot to confirm proper shortening.

  • A rail shortened by more than 3 mm, with properly finished edges, will also function correctly. Please see the photo with slots of different rail lengths.

     

After completing all steps, all rails are shortened, edges are smoothed, shavings are removed, and the risk of battery housing damage has been eliminated.