Production process of lower box of power battery and lower box of power battery

Abstract

The application relates to the technical field of a battery box production process, and discloses a production process of a lower box of a power battery and the lower box of the power battery. The production process comprises the following steps: aluminum ingot smelting, pressure casting to obtain a blank, first machining, second friction welding, third machining, fourth machining, installation of a water nozzle and an explosion-proof valve, and assembly of a support. Through the first machining, the second friction welding, the third machining and the fourth machining, surface treatment, drilling, tapping and other processes of the lower box of the battery are realized, and a cooling cavity is formed on the lower box of the battery. Through the water nozzle and the explosion-proof valve assembly equipment, the water nozzle and the explosion-proof valve can be simultaneously assembled on the lower box of the battery, the process of preparing the lower box of the battery can be shortened, through the support assembly equipment, supports with different sizes can be assembled on the lower box of the battery, the lower box of the battery and the support are arranged in a split type, and the application can be suitable for use in different vehicle models.

Description

Technical Field

[0001] This invention relates to the technical field of battery housing manufacturing processes, and particularly to a manufacturing process for a power battery lower housing and the power battery lower housing itself. Background Technology

[0002] The power battery is the electrical power supply device for an electric vehicle, consisting of a power battery housing and a battery pack housed within it. To ensure the structural strength of the power battery and protect the battery pack, a battery housing is installed on the outside of the power battery. The battery housing consists of an upper housing and a lower housing. The upper housing mainly serves to protect the battery modules, while the lower housing mainly functions as a load-bearing component and needs to have sufficient strength and rigidity.

[0003] Existing manufacturing processes for battery lower housings generally include aluminum ingot smelting, die casting into blanks, machining the blanks to create a smooth surface, forming corresponding hole structures on the blanks, and installing water inlets, explosion-proof valves, etc., in the corresponding holes. Many processes still rely on manual installation, such as installing water inlets and explosion-proof valves. Furthermore, manual installation of water inlets and explosion-proof valves requires separate processes, resulting in low installation efficiency and difficulty in achieving standardized installation requirements. In addition, the finished battery lower housing typically has multiple brackets integrally formed on both sides. These brackets provide a stable framework for the battery lower housing, ensuring proper installation at the bottom of the vehicle. However, when the battery lower housing and brackets are die-cast as a single unit, it is not possible to adapt to different vehicle models by replacing brackets of different sizes, thus limiting the application of the battery lower housing.

[0004] It is evident that existing technologies still need improvement and enhancement. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a manufacturing process for a power battery lower housing and a power battery lower housing, which allows the bracket to be independently installed on the mounting part of the battery lower housing, so that the power battery lower housing produced by this manufacturing process can be used in different vehicle models.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A manufacturing process for the lower casing of a power battery includes the following steps: aluminum ingot smelting and die casting to obtain a blank, and further includes the following steps:

[0008] First machining: Two water nozzle holes are machined on one side wall of the blank, a friction welding trajectory surface is machined on the rear side of the blank, and positioning holes on the positioning ears of the blank are machined.

[0009] Second friction welding: The sealing plate is welded to the above-mentioned trajectory surface to form a cooling cavity on the lower battery casing;

[0010] Third machining: Machining the front and two sides of the mounting part on the lower battery box, machining the first threaded hole on the front of the mounting part on the lower battery box, machining the explosion-proof valve hole on one side wall of the lower battery box, wherein the explosion-proof valve hole and the water tap hole are located on opposite side walls of the lower battery box.

[0011] Fourth machining: Machining the third threaded holes on both sides of the mounting part on the lower battery casing, and machining the second threaded hole in the inner cavity of the lower battery casing;

[0012] Install the faucets and explosion-proof valves: Install the two faucets into the corresponding faucet holes, and install the explosion-proof valve into the explosion-proof valve hole;

[0013] Assemble the bracket: Fasten the bracket to the first threaded hole and the third threaded hole with bolts.

[0014] The manufacturing process of the lower battery housing includes the following steps after the bracket assembly is completed: applying adhesive to the gaps between the lower battery housing and the bracket, the gaps between the lower battery housing and the explosion-proof valve, and the gaps between the bracket and the bolts.

[0015] The manufacturing process of the lower battery casing includes a first cleaning step between the first machining and the second friction welding. The first cleaning step includes cleaning the sealing plate and cleaning the rear side of the lower battery casing.

[0016] The manufacturing process of the lower battery casing includes an electrophoresis process and an insulating powder spraying process for the lower battery casing between the fourth machining step and the installation of the water nozzle and explosion-proof valve.

[0017] The production process of the lower battery casing includes a second cleaning process after the insulating powder spraying process. The second cleaning process includes cleaning the lower battery casing using a through-type cleaning line.

[0018] The manufacturing process of the lower battery casing includes a step of affixing labels to the lower battery casing after the second cleaning step.

[0019] The manufacturing process of the lower battery housing includes an airtightness testing process between the water inlet and the explosion-proof valve and the assembly bracket. The airtightness testing process includes leak testing of the inner cavity and the cooling cavity of the lower battery housing.

[0020] The manufacturing process of the lower housing of the power battery includes a process where, after the die-cast blank is obtained, the entire surface of the blank needs to be polished and deburred.

[0021] The manufacturing process of the lower battery housing includes a shot blasting process after the deburring is completed.

[0022] A power battery lower casing is manufactured using the same manufacturing process as described above.

[0023] Beneficial effects:

[0024] This invention provides a manufacturing process for a power battery lower housing and the power battery lower housing itself. Through a first machining step, a second friction welding step, a third machining step, and a fourth machining step, the surface treatment, drilling, and tapping of the battery lower housing are achieved, forming a cooling cavity on the battery lower housing. A water nozzle and explosion-proof valve assembly device allows for the simultaneous assembly of a water nozzle and an explosion-proof valve onto the battery lower housing, shortening the manufacturing process. A bracket assembly device allows for the assembly of brackets of different sizes onto the battery lower housing, making the battery lower housing and brackets separate units suitable for various vehicle models. Attached Figure Description

[0025] Figure 1 A flowchart illustrating the manufacturing process of the lower housing of the power battery provided by this invention.

[0026] Figure 2 This is a structural schematic diagram of the bracket assembly equipment.

[0027] Figure 3 A partial structural diagram of the bracket assembly equipment. Figure 1 .

[0028] Figure 4 A partial structural diagram of the bracket assembly equipment. Figure 2 .

[0029] Figure 5 This is a structural diagram of the bracket assembly equipment after the lower housing of the power battery is installed.

[0030] Figure 6 This is a schematic diagram of the lower battery housing without the bracket installed.

[0031] Figure 7 Schematic diagram of the glue dispensing equipment Figure 1 .

[0032] Figure 8 Schematic diagram of the glue dispensing equipment Figure 2 .

[0033] Figure 9 Schematic diagram of the positioning plate Figure 1 .

[0034] Figure 10Schematic diagram of the positioning plate Figure 2 .

[0035] Figure 11 This is a schematic diagram of the positioning plate when the power battery is not installed in the lower housing.

[0036] Figure 12 Schematic diagram of the lower housing of the power battery Figure 1 .

[0037] Figure 13 for Figure 12 Enlarged view of part P in the middle.

[0038] Figure 14 Schematic diagram of the lower housing of the power battery Figure 2 .

[0039] Figure 15 This is a schematic diagram of the scanning mechanism.

[0040] Explanation of key component symbols: E - water tap and explosion-proof valve assembly equipment, F - bracket assembly equipment, G - glue application equipment;

[0041] F10 - Operating station, F21 - First frame, F22 - Cam divider, F23 - Motor, F24 - Turntable, F25 - Support column, F26 - First positioning pin, F27 - Bracket clamping mechanism, F28 - Second positioning pin, F3 - Tightener, F41 - First sensing component, F5 - Bracket marking device, F51 - Support, F52 - Slide plate, F53 - First lifting cylinder, F54 - First marking device, F55 - Second marking device;

[0042] G1-Flipping frame, G2-Flipping mechanism, G3-Positioning plate, G31-Second sensing component, G4-Positioning mechanism, G41-Support base, G42-Glue application positioning pin, G43-Protective pad, G44-First glue application anti-misalignment block, G441-Allowing groove, G45-Second glue application anti-misalignment block, G46-Third glue application anti-misalignment block, G47-Fourth glue application anti-misalignment block, G48-Anti-collision bar, G51-First clamping component, G511-First clamping cylinder, G512-Connecting rod, G513-Pressure plate, G51 4-First pressure head, G515-Hinge seat, G52-Second pressing assembly, G521-Second pressing cylinder, G522-Rotating arm, G523-Second pressure head, G6-Mechanical arm, G7-Glue application mechanism, G8-Scanning mechanism, G81-Base plate, G82-Fixing plate, G821-Scanning threaded hole, G822-Arc hole, G823-Locking component, G83-Support plate, G84-Protective cover, G85-Scanning camera, G9-Alignment mounting bracket, G91-Alignment placement seat, G92-Through-beam optical fiber;

[0043] 1-Battery lower casing, 11-Mounting part, 111-First threaded hole, 112-Third threaded hole, 12-Second threaded hole, 13-Positioning ear, 14-Positioning hole, 15-Rectangular through hole, 17-Explosion-proof valve hole, 18-Sealing plate, 2-Bracket, 21-Bolt, 3-Water nozzle, 4-Explosion-proof valve, 5-Glue sealing layer. Detailed Implementation

[0044] This invention provides a manufacturing process for the lower casing of a power battery and the lower casing itself. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the scope of protection of the invention.

[0045] Please see Figure 1 The present invention provides a manufacturing process for the lower casing of a power battery, including the following steps: aluminum ingot smelting, die casting to obtain a blank, grinding to remove burrs, and shot blasting.

[0046] After aluminum ingots are purchased and delivered to the factory, they need to undergo tests such as chemical composition, density, and hardness. The aluminum ingots that meet the requirements are melted and poured into molds, and then die-cast to produce the battery lower casing blank.

[0047] The surface of the die-cast blank is relatively rough and irregular, or there may be air holes. Therefore, the blank is polished and shot-blasted to make the surface of the battery lower box 1 smooth, remove the burrs and sharp edges on the surface, and provide better surface roughness and adhesion for subsequent processes such as electroplating and spraying insulating powder, thereby enhancing the corrosion resistance of the battery lower box 1.

[0048] It should be noted that this embodiment is described with the water nozzle located on the right side of the lower battery housing 1, the explosion-proof valve 4 located on the left side of the lower battery housing 1, the inner cavity as the front, and the sealing plate 18 as the back.

[0049] Specifically, the lower battery housing 1 of the present invention is provided with six mounting parts 11 on the upper and lower sides, with three mounting parts 11 on each side. The two upper mounting parts 11 are also provided with positioning ears 13 integrally die-cast with the lower battery housing 1.

[0050] The lower battery housing 1, after surface treatment, also includes the following processes:

[0051] First machining step: Two water nozzle holes are machined on one side wall (right side) of the blank, one of which is a water inlet and the other is a water outlet, allowing cooling water to circulate within them. A friction welding trajectory surface is machined on the rear side of the blank to facilitate a tight connection with the sealing plate 18 in subsequent processes. The positioning ears 13 on the blank also need to be machined to form positioning holes 14. These two positioning holes 14 are used for positioning in subsequent processing equipment, ensuring the lower battery casing 1 is correctly positioned and fixed in the corresponding processing equipment.

[0052] First cleaning: Clean the sealing plate 18 and the rear side of the lower battery casing 1. After the first machining, the surface of the lower battery casing 1 has a lot of metal shavings, so its rear side needs to be cleaned, and the sealing plate 18 to be welded also needs to be cleaned.

[0053] Second friction welding: The sealing plate 18 is welded to the aforementioned trajectory surface to form a cooling cavity on the lower battery housing 1. The lower battery housing 1 is provided with an inner cavity and a cooling cavity. The inner cavity is used to house the battery module. Multiple cooling channels are formed on the rear side of the lower battery housing 1. Cooling water enters through the aforementioned water inlet and flows through the cooling channels, then flows out through the aforementioned water outlet. The sealing plate 18 is welded to the rear side of the lower battery housing 1 to form the cooling cavity, preventing cooling water from flowing out. Water cooling is used to cool the battery module in the inner cavity. After heat exchange, the temperature of the cooling water rises, flows out of the lower battery housing 1, is cooled, and then re-enters the cooling cavity to achieve circulating water cooling.

[0054] The third machining step involves machining the front and two sides of the mounting portion 11 on the lower battery housing 1, machining the first threaded hole 111 on the front of the mounting portion 11, and machining the explosion-proof valve hole 17 on one side wall (left side) of the lower battery housing 1. The explosion-proof valve hole 17 and the water tap hole are located on opposite side walls of the lower battery housing 1. To improve the fit between the upper surface and two sides of the mounting portion 11 and the lower surface of the bracket 2, the front and two sides of the six mounting portions 11 need to be machined to make their surfaces smoother. The explosion-proof valve hole 17 also needs to be opened on the left side of the lower battery housing 1. In this embodiment, the first and third machining steps use the same set of clamping molds to fix the lower battery housing 1.

[0055] Fourth machining step: Machining the second threaded holes 112 on both sides of the mounting part 11 on the lower battery housing 1, and machining the second threaded holes 12 in the inner cavity of the lower battery housing 1. The second threaded holes 12 are distributed throughout the inner cavity. The main function of the second threaded holes 12 is to fix the battery module in the inner cavity of the lower battery housing 1, and to fix it to the upper battery housing cover, so that the battery module is in a sealed state.

[0056] Electrophoresis and Insulating Powder Spraying: The lower battery casing 1 undergoes an electrophoresis process and insulating powder spraying. Electrophoresis forms a one-sided electrophoretic coating on the surface of the lower battery casing 1. This coating provides excellent corrosion resistance, preventing the lower battery casing 1 from being eroded by moisture and chemicals, and provides insulation protection. Insulating powder spraying is generally made of inorganic materials, such as ceramics or polymer composites. Spraying insulating powder onto the lower battery casing 1 increases the insulation performance of its surface, blocking the effects of moisture and environmental humidity on the battery's internal structure.

[0057] The second cleaning process involves a through-line cleaning system for the lower battery housing 1. The lower battery housing 1, which has been coated with both electrophoretic and insulating coatings, is placed on a conveyor line. Cleaning nozzles on the conveyor line then perform a thorough cleaning of the lower battery housing 1 to remove dust and other contaminants from its surface.

[0058] Print and affix QR code labels: Affix labels to the lower battery housing 1. Each lower battery housing 1 has a unique QR code identifier, which is equivalent to the identity card of the lower battery housing 1. In the subsequent process, the QR code identifier will be scanned before each process and the information will be entered into the control system to achieve the purpose of product traceability.

[0059] Installing the water taps 3 and explosion-proof valves 4: Install the two water taps 3 into their corresponding water tap holes, and install the explosion-proof valve 4 into the explosion-proof valve hole 17. This process of installing the water taps 3 and explosion-proof valves 4 is completed using a water tap and explosion-proof valve assembly device E. The worker places the two water taps 3 into their respective water tap holes and the explosion-proof valve 4 into the explosion-proof valve holder on the assembly device E. Through the operation of the assembly device E, the two water taps 3 are installed into their corresponding water tap holes one by one, while simultaneously, the explosion-proof valve 4 is installed into the explosion-proof valve hole 17. This process allows for the simultaneous assembly of the water taps 3 and explosion-proof valves 4 using a single assembly device, resulting in higher assembly efficiency and accuracy compared to manual assembly.

[0060] Air tightness test: Leakage test is performed on the inner cavity and cooling cavity of the lower battery housing 1. The sealing performance of the inner cavity and cooling cavity is determined by filling the inner cavity and cooling cavity with air or by evacuating the inner cavity and cooling cavity, and then detecting the change in air pressure in the inner cavity and cooling cavity over a period of time, so as to ensure that the inner cavity and cooling cavity are sealed.

[0061] Assemble bracket 2: Secure bracket 2 to the first threaded hole 111 and the third threaded hole 112 with bolts 21. After passing the gasket and bolt 21 through the first threaded hole 111 and the third threaded hole 112 one by one, tighten the bolt 21 with the tightener F3 on the bracket assembly equipment F, and fix the six brackets 2 to the corresponding mounting parts 11 one by one.

[0062] Sealing bracket 2 and explosion-proof valve 4: Sealing is applied to the gaps between the lower battery housing 1 and bracket 2, between the lower battery housing 1 and explosion-proof valve 4, and between bracket 2 and bolt 21. When the ambient humidity is high, or when the vehicle generates moisture during use, such as humid air or rainwater entering from the surrounding environment, this moisture may accumulate on the outer wall of the battery housing. Due to gravity, the moisture flows into the gaps between the lower battery housing 1 and bracket 2, between the lower battery housing 1 and explosion-proof valve 4, and between bracket 2 and bolt 21. The moisture in these gaps is difficult to evaporate, and over time, the accumulated water in the gaps will slowly corrode the lower battery housing 1 and bracket 2. Therefore, sealing these gaps with sealant solves the problem of water accumulation and corrosion of the lower battery housing 1.

[0063] Full appearance inspection: The overall appearance of the finished battery lower casing 1 is inspected. After the battery lower casing 1 has undergone each process, each process will mark the battery lower casing 1. After marking, multiple marks will be formed on the surface of the battery lower casing 1. This full appearance inspection process specifically checks the multiple marks formed on the surface of the battery lower casing 1 in each process to ensure that the product flowing to the next process is a qualified product.

[0064] Packaging and Shipping: Pack and ship the finished battery lower casing 1 that has passed the above inspection.

[0065] This production process covers the entire process flow of the battery lower casing 1. Die casting, deburring, and shot blasting are used to improve the surface finish of the battery lower casing 1. First machining, second friction welding, third machining, and fourth machining processes are used to perform surface treatment, drilling, tapping, and other machining on the battery lower casing 1, forming a cooling cavity on it. Secondary cleaning keeps the battery lower casing 1 clean. Electrophoresis and spraying insulating powder form a protective layer on the surface of the battery lower casing 1. Water nozzles 3 and explosion-proof valves 4 can be simultaneously assembled on the battery lower casing 1 using the water nozzle and explosion-proof valve assembly equipment E, which can shorten the manufacturing time of the battery lower casing. The process involves several steps: 1) Using an airtightness testing device, the sealing performance of the inner cavity and cooling cavity of the lower battery housing 1 can be tested; 2) Using a bracket assembly device F, brackets 2 of different sizes can be assembled onto the lower battery housing 1, making the lower battery housing 1 and brackets 2 separate units suitable for different vehicle models; 3) Using a sealant applicator G, the gaps between the lower battery housing 1 and brackets 2, between the lower battery housing 1 and the explosion-proof valve 4, and between brackets 2 and bolts 21 can be sealed to solve the problem of water accumulation and corrosion of the lower battery housing 1 in these gaps; 4) Finally, a full visual inspection is conducted to prevent defective products from reaching customers.

[0066] Please see Figures 2-6In some embodiments, the bracket assembly equipment F includes a first frame F21, a cam divider F22 mounted on the first frame F21, a motor F23 driven by the cam divider F22, and a turntable F24 mounted on the output end of the cam divider F22. The turntable F24 is provided with a support column F25 for supporting the lower battery housing 1, a first positioning pin F26 for positioning the lower battery housing 1, and a bracket clamping mechanism F27 for pressing the lower battery housing 1 onto the support column F25. The turntable F24 is also provided with a second positioning pin F28, which is the same number as the mounting parts 11 of the lower battery housing 1 and is used to mate with the holes on the bracket 2. The first frame F21 is provided with a tightener F3 for tightening the bolts 21.

[0067] Please see Figure 2 To standardize worker operations, an operating station F10 is set up in front of the first frame F21. When the worker stands at the operating station F10, the front of the worker's body faces the turntable F24 behind.

[0068] During assembly, the worker first moves the lower battery housing 1 onto the turntable F24. Then, the support column F25 supports the bottom of the lower battery housing 1, and the two first positioning pins F26 are matched with the positioning holes 14 on the positioning ears 13, thereby basically fixing the position of the lower battery housing 1. Next, the bracket clamping mechanism F27 presses the lower battery housing 1 onto the support column F25 to completely fix the lower battery housing 1. At this time, one side of the lower battery housing 1 faces the worker, who can install the bracket 2 on the three mounting parts 11 on this side. The bracket 2 not only cooperates with the mounting parts 11, but also uses the second positioning pin F28 to cooperate with the holes on the bracket 2 to achieve positioning and support of the bracket 2, ensuring that the first threaded hole 111 and the third threaded hole 112 are aligned with the mounting holes. Then, the worker passes the bolt 21 through the mounting hole and inserts it into the first threaded hole 111 or the third threaded hole 112. Finally, the worker uses the tightening device F3 to tighten the bolt 21 to complete the assembly of the bracket 2. After the bracket 2 on one side of the battery lower housing 1 is installed, the motor F23 drives the cam divider F22 to rotate the turntable F24 by 180°, so that the other side of the battery lower housing 1 faces the worker. The worker then continues to install the bracket 2 on the three mounting parts 11 on the other side and secure the bracket 2 with bolts 21. After all brackets 2 are assembled, the motor F23 drives the cam divider F22 to rotate the turntable F24 by 180°, and the turntable F24 rotates back to its original position. The bracket clamping mechanism F27 releases the battery lower housing 1, and the worker unloads the battery lower housing 1. Specifically, each bolt 21 is fitted with a washer to ensure a secure connection between the bolt 21 and the first threaded hole 111 and the third threaded hole 112.

[0069] Please see Figure 3 In some embodiments, the bracket clamping mechanism F27 includes four clamping cylinders, two of which are used to press one end of the lower battery housing 1, and the other two are used to press the other end of the lower battery housing 1; each clamping cylinder has a bracket clamping head on its output end. The clamping cylinders, in conjunction with the bracket clamping heads, can quickly complete clamping or releasing operations, improving work efficiency. Its response is rapid; clamping of the lower battery housing 1 can be achieved by controlling the air source, providing reliable clamping force. Furthermore, when the bracket clamping head is not clamping, it can also avoid interference with the placement and removal of the lower battery housing 1.

[0070] Please see Figure 3 In some embodiments, the turntable F24 is provided with a first sensing component F41 for detecting whether the lower battery housing 1 is correctly placed on the turntable F24. The first sensing component F41 specifically consists of three photoelectric sensors arranged in a triangular pattern. When all three photoelectric sensors simultaneously provide feedback signals, it indicates that the lower battery housing 1 is placed and clamped in place; conversely, if one or more photoelectric sensors do not provide feedback signals, it means that the lower battery housing 1 is not placed in place.

[0071] Please see Figure 3 In some embodiments, the first frame F21 is further equipped with a bracket marking device F5. The first frame F21 is equipped with an electronic controller and a vision camera electrically connected to the electronic controller. The vision camera is used to take pictures of the bracket 2 after it is fixed to the lower battery housing 1 by bolts 21. It can be understood that after the bracket 2 on one side of the lower battery housing 1 is installed, the turntable F24 rotates 180° so that the side of the lower battery housing 1 faces the bracket marking device F5. At this time, the vision camera takes pictures of the assembly drawing of the bracket 2 on this side of the lower battery housing 1 and uploads it to the electronic controller. It is compared with the pre-set qualified assembly drawing. If the comparison is correct, the bracket marking device F5 marks the lower battery housing 1 to indicate that it is qualified. If the comparison is incorrect, the bracket marking device F5 does not mark the lower battery housing 1. It can intelligently detect the situation of missing bolts 21, missing bolts, and bolts that are not tightened, thereby improving product quality.

[0072] Please see Figure 3 and Figure 4Specifically, the bracket marking device F5 includes a support F51, a sliding plate F52 that is slidably connected to the support F51 and can move vertically, a first lifting cylinder F53 for driving the sliding plate F52 to rise and fall, and a first marking device F54 and a second marking device F55 disposed on the sliding plate F52. The first marking device F54 is used to mark one side of the lower battery housing 1, and the second marking device F55 is used to mark the other side of the lower battery housing 1. When the bracket marking device F5 is in the non-marking state, the output end of the first lifting cylinder F53 extends, driving the slide plate F52 and the first marking device F54 and the second marking device F55 on the slide plate F52 to rise to the highest point, so as not to interfere with the placement and disassembly of the battery lower box 1. When marking is required, the first lifting cylinder F53 drives the slide plate F52 and the first marking device F54 and the second marking device F55 on the slide plate F52 to descend, and the first marking device F54 / second marking device F55 is selected for marking as needed.

[0073] Please see Figures 7-15 In some embodiments, the glue application equipment G includes a flipping frame G1, a positioning plate G3, a flipping mechanism G2, a battery lower casing clamping mechanism, a robotic arm G6, and a glue application mechanism G7. The flipping frame G1 is equipped with the flipping mechanism G2, which is fixedly connected to the positioning plate G3. The battery lower casing clamping mechanism is located on the positioning plate G3 and is used to fix the battery lower casing 1 to the upper surface of the positioning plate G3. The flipping mechanism G2 is used to drive the positioning plate G3 and the battery lower casing 1 to flip at a set angle. The robotic arm G6 is located on one side of the flipping mechanism G2 and is fixedly connected to the glue application mechanism G7. The robotic arm G6 is used to drive the glue application mechanism G7 to apply glue to the gaps between the battery lower casing 1 and the bracket 2, the gaps between the battery lower casing 1 and the explosion-proof valve 4, and the gaps between the bracket 2 and the bolt 21.

[0074] Specifically, in this embodiment, the flipping mechanism G2 is a programmed motor-driven positioning plate G3 that flips at a set angle. For example, after flipping the positioning plate G3 and the lower battery housing 1 backward by 90°, the robotic arm G6 drives the gluing mechanism G7 to apply glue to the support 2 and explosion-proof valve 4 in front of the lower battery housing 1. Alternatively, after flipping the positioning plate G3 and the lower battery housing 1 forward by 90°, the robotic arm G6 drives the gluing mechanism G7 to apply glue to the support 2 behind the lower battery housing 1. The specific flipping angle and flipping process are not limited in this invention. More specifically, in this embodiment, the gluing mechanism G7 is a glue gun, which uses a two-component adhesive mixed in a certain proportion and can be cured at room temperature or under heating conditions.

[0075] In practical use, the worker places the battery lower casing 1, to be glued, on the upper surface of the positioning plate G3. The control mechanism drives the battery lower casing clamping mechanism to fix the battery lower casing 1 to the upper surface of the positioning plate G3. Subsequently, the control mechanism drives the flipping mechanism G2, the robotic arm G6, and the gluing mechanism G7 to operate synchronously or asynchronously. This allows the gluing mechanism G7 to apply glue to the gaps between the bracket 2 and the outer wall of the battery lower casing 1 after flipping, as well as the gaps between the bracket 2 and the gasket, and the gap between the battery lower casing 1 and the explosion-proof valve 4. After the adhesive cures, a glue sealing layer 5 is formed. The glue sealing layer 5 seals the gaps and, due to its hydrophobicity, prevents moisture from accumulating on it. After gluing is completed, the flipping mechanism G2 resets the positioning plate G3 and the battery lower casing 1, and the battery lower casing clamping mechanism releases the force on the battery lower casing 1, allowing the worker to unload the battery lower casing 1.

[0076] Please see Figures 9-11 In some embodiments, the upper surface of the positioning plate G3 is provided with a positioning mechanism G4. The positioning mechanism G4 includes multiple support seats G41 disposed on the upper surface of the positioning plate G3 and a first glue-applying anti-misalignment block G44, a second glue-applying anti-misalignment block G45, a third glue-applying anti-misalignment block G46, and a fourth glue-applying anti-misalignment block G47. The upper surfaces of the multiple support seats G41 respectively abut against the lower surface of the lower battery housing 1, and glue-applying positioning is fixedly connected in two or more of the support seats G41. Pin G42, the upper part of which is used to insert into the positioning hole 14 in the positioning ear 13 of the lower battery housing 1; the first glue-applying anti-misalignment block G44 is located on one side of the explosion-proof valve 4, and the second glue-applying anti-misalignment block G45, the third glue-applying anti-misalignment block G46 and the fourth glue-applying anti-misalignment block G47 are all located in the rectangular through hole 15 of the lower battery housing 1, and the third glue-applying anti-misalignment block G46 and the fourth glue-applying anti-misalignment block G47 are symmetrically arranged along the second glue-applying anti-misalignment block G45. When the worker places the lower battery box 1 on the upper surface of the positioning plate G3, it is necessary to ensure that the lower battery box 1 is placed on the upper surface of the positioning plate G3 in the correct loading position. The positions of the multiple glue-applying anti-fool blocks are adapted to the shape of the lower battery box 1 and the position of the rectangular through hole 15. The multiple support seats G41 and glue-applying positioning pins G42 are also adapted to the shape of the lower battery box 1 and the positioning holes 14 of the positioning ears 13 on the lower battery box 1. After the lower battery box 1 is loaded, the control mechanism drives the lower battery box pressing mechanism to operate and fix the lower battery box 1 on the upper surface of the positioning plate G3.

[0077] Please see Figure 9 and Figure 11Specifically, the upper surface of the support base G41, which does not have a glued positioning pin G42, is provided with a protective pad G43, and the upper surface of the protective pad G43 abuts against the lower surface of the lower battery housing 1. This arrangement can be used to protect the appearance of the lower battery housing 1 and prevent scratches.

[0078] Please see Figure 11 In some embodiments, a second sensing component G31 is further provided on the upper surface of the positioning plate G3. The second sensing component G31 is used to detect whether the lower battery housing 1 is placed on the positioning plate G3. Specifically, in this embodiment, the second sensing component G31 consists of three photoelectric sensors: one photoelectric sensor is located on the left side of the positioning plate G3, and two photoelectric sensors are located on the right side of the positioning plate G3, arranged in a triangular pattern. The second sensing component G31 has the same function as the first sensing component F41. The second sensing component G31 is electrically connected to the control mechanism and transmits information on whether the material loading on the positioning plate G3 is complete to the control mechanism through signal transmission, thereby driving the control mechanism to start other mechanisms to operate, which can improve the automation level of the glue application device.

[0079] Please see Figure 9 and Figure 11 In some embodiments, the battery lower housing clamping mechanism includes a first clamping component G51 and a second clamping component G52. The first clamping component G51 is located on one side of the explosion-proof valve 4, and the second clamping component G52 is located in the rectangular through hole 15 of the battery lower housing 1. The first clamping component G51 includes a first clamping cylinder G511, a connecting rod G512, a pressure plate G513, a first pressure head G514, and a hinge seat G515. The output end of the first clamping cylinder G511 is vertically oriented towards... The first pressing cylinder G511 is configured such that the output end of the first pressing cylinder G511 is fixedly connected to the connecting rod G512. The upper part of the connecting rod G512 is hinged to the lower part of the pressure plate G513. The upper part of the pressure plate G513 is fixedly connected to the first pressure head G514. The hinge seat G515 is disposed on the upper surface of the first pressing cylinder G511 and is hinged to the middle part of the pressure plate G513. The lower surface of the first pressure head G514 is used to abut against the upper surface of the lower battery housing 1. When the output end of the first pressing cylinder G511 is in the retracted state, the connecting rod G512 pulls the lower part of the pressure plate G513 downward, causing the upper part of the pressure plate G513 to drive the first pressure head G514 upward, releasing the pressing force on the upper surface of the left side of the lower battery housing 1 and providing clearance for the unloading of the lower battery housing 1. The reason for using the above structure instead of a rotary cylinder is that when the rotary cylinder rotates, it will occupy the space of the explosion-proof valve 4 located on the side of the first pressing assembly G51, which will reduce the operable space of the gluing mechanism G7.

[0080] Please see Figure 9 and Figure 11 In some embodiments, the height of the first glue-applying anti-misalignment block G44 is greater than the height of the lower battery housing 1. A U-shaped clearance groove G441 is provided on the upper part of the first glue-applying anti-misalignment block G44. The first pressing cylinder G511 is used to drive the first pressing head G514 to move up and down within the clearance groove G441. The first glue-applying anti-misalignment block G44 is located behind the explosion-proof valve 4, and the first pressing assembly G51 is located to the left of the first glue-applying anti-misalignment block G44. There is a certain distance between the placement positions of the first glue-applying anti-misalignment block G44 and the first pressing assembly G51 and the explosion-proof valve 4, providing more operating space for the glue-applying mechanism G7. The clearance groove G441 on the first glue-applying anti-misalignment block G44 provides clearance when the first pressing head G514 is pressed down and raised, a clever design.

[0081] Please see Figure 11 In some embodiments, two second clamping components G52 are symmetrically arranged along the second glue-applying anti-misalignment block G45. Each of the two second clamping components G52 includes a second clamping cylinder G521, a rotating arm G522, and a second pressure head G523. The second clamping cylinder G521 is a rotary cylinder. The rotating arm G522 is located at the output end of the second clamping cylinder G521, and the second pressure head G523 is fixedly connected to the end of the rotating arm G522. The lower surface of the second pressure head G523 is used to abut against the upper surface of the lower battery housing 1. The two second clamping components G52 are located between the third glue-applying anti-misalignment block G46 and the fourth glue-applying anti-misalignment block G47, and the second glue-applying anti-misalignment block G45 is located between the third glue-applying anti-misalignment block G46 and the fourth glue-applying anti-misalignment block G47. When the output end of the second clamping cylinder G521 rises, driving the rotating arm G522 and the second pressure head G523 to rotate outward, the clamping force on the upper surface of the right side of the lower battery housing 1 is released; when the output end of the second clamping cylinder G521 descends, driving the rotating arm G522 and the second pressure head G523 to rotate inward, the upper surface of the right side of the lower battery housing 1 is clamped. The above structure makes full use of the space between the third glue-applying anti-misalignment block G46 and the fourth glue-applying anti-misalignment block G47, limiting the loading position of the lower battery housing 1 while also clamping the lower battery housing 1, making the glue-applying device structure more compact.

[0082] Please see Figure 9 and Figure 11In some embodiments, the height of the third and fourth glue-applying anti-misalignment blocks G46 and G47 is greater than the height of the lower battery housing 1, and a bumper bar G48 is fixedly connected to the upper part of the third and fourth glue-applying anti-misalignment blocks G46 and G47, with the second clamping assembly G52 located below the bumper bar G48. When the robotic arm G6 drives the glue-applying mechanism G7, it will pass over the bumper bar G48. Therefore, the bumper bar G48 is provided to prevent the glue-applying mechanism G7 from colliding with the second clamping assembly G52 and the right side of the lower battery housing 1, thus providing protection.

[0083] Please see Figure 15 In some embodiments, the flipping frame G1 is further equipped with a barcode scanning mechanism G8. The barcode scanning mechanism G8 includes a fixed base mounted on the flipping frame G1, a protective cover G84 mounted on the upper surface of the fixed base, and a barcode scanning camera G85 located inside the protective cover G84. The barcode scanning camera G85 is used to identify the identification code of the lower battery housing 1 fixed on the positioning plate G3. Since the manufacturing process of the lower battery housing 1 requires multiple steps, each step corresponding to an identification code, after the worker loads the material, the identification code on the lower battery housing 1 needs to be identified by the barcode scanning camera G85 and entered into the control system to achieve traceability.

[0084] Please see Figure 15 In some embodiments, the fixing base includes a base plate G81, two fixing plates G82, and a support plate G83; the base plate G81 abuts against the lower surface of the flipping frame G1, the two fixing plates G82 are symmetrically arranged on the upper surface of the base plate G81, the support plate G83 is fixedly connected between the two fixing plates G82, and the lower surface of the protective cover G84 is fixedly connected to the upper surface of the support plate G83; each of the two fixing plates G82 is provided with a barcode scanning threaded hole G821 and an arc-shaped hole G822, and a locking member G823 is provided in both the barcode scanning threaded hole G821 and the arc-shaped hole G822, the locking member G823 fixing the support plate G83 between the two fixing plates G82. The above configuration allows the angles of the support plate G83 and the barcode scanner G85 mounted on the upper surface of the support plate G83 to be adjustable. By adjusting the position of the locking member G823 in the arc-shaped hole G822, the tilt angle of the support plate G83 can be changed, enabling the barcode scanner G85 to accurately identify the identification code on the lower battery housing 1.

[0085] Please see Figure 7 and Figure 8In some embodiments, a benchmark mounting bracket G9 is provided on one side wall of the flipping frame G1 facing the robotic arm G6. A benchmark placement seat G91 is provided on the upper surface of the benchmark mounting bracket G9. All four sides of the benchmark placement seat G91 have clearance holes, and each clearance hole contains a through-beam optical fiber G92. The benchmark placement seat G91 has a hollow structure, and multiple through-beam optical fibers G92 are used to sense the gluing mechanism G7 inserted into the cavity of the benchmark placement seat G91. For example, after each gluing operation is completed, the robotic arm G6 needs to drive the gluing mechanism G7 to reset to the benchmark placement seat G91. The multiple through-beam optical fibers G92 ensure that the gluing mechanism G7 is reset in place.

[0086] In summary, this invention improves the surface finish of the battery lower housing 1 through die casting, deburring, and shot blasting; performs surface treatment, drilling, and tapping on the battery lower housing 1 through first machining, second friction welding, third machining, and fourth machining, and forms a cooling cavity on the battery lower housing 1; maintains the cleanliness of the battery lower housing 1 through secondary cleaning; forms a protective layer on the surface of the battery lower housing 1 through electrophoresis and spraying insulating powder; and allows for the simultaneous assembly of water nozzles 3 and explosion-proof valves 4 on the battery lower housing 1 using the water nozzle and explosion-proof valve assembly equipment E, thus shortening the manufacturing process of the battery lower housing 1. The airtightness testing equipment can test the sealing performance of the inner cavity and cooling cavity of the lower battery housing 1; the bracket assembly equipment F can assemble brackets 2 of different sizes onto the lower battery housing 1, making the lower battery housing 1 and brackets 2 separate units, suitable for use in different vehicle models; the glue application equipment G can seal the gaps between the lower battery housing 1 and brackets 2, between the lower battery housing 1 and the explosion-proof valve 4, and between brackets 2 and bolts 21, to solve the problem of water accumulation and corrosion of the lower battery housing 1 in the above gaps; finally, a full visual inspection is conducted to prevent defective products from reaching customers.

[0087] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0088] Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," or "third" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0089] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows for communication; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0090] It is understood that those skilled in the art can make equivalent substitutions or changes to the technical solution and inventive concept of the present invention, and all such changes or substitutions should fall within the protection scope of the present invention.

Claims

1. A manufacturing process for the lower casing of a power battery, comprising the following steps: aluminum ingot smelting, die casting to obtain a blank, characterized in that, It also includes the following steps: First machining: Two water nozzle holes are machined on one side wall of the blank, a friction welding trajectory surface is machined on the rear side of the blank, and positioning holes on the positioning ears of the blank are machined. Second friction welding: The sealing plate is welded to the above-mentioned trajectory surface to form a cooling cavity on the lower battery casing; Third machining: Machining the front and two sides of the mounting part on the lower battery box, machining the first threaded hole on the front of the mounting part on the lower battery box, machining the explosion-proof valve hole on one side wall of the lower battery box, wherein the explosion-proof valve hole and the water tap hole are located on opposite side walls of the lower battery box. Fourth machining: Machining the third threaded holes on both sides of the mounting part on the lower battery casing, and machining the second threaded hole in the inner cavity of the lower battery casing; Install the faucets and explosion-proof valves: Install the two faucets into the corresponding faucet holes, and install the explosion-proof valve into the explosion-proof valve hole; Assemble the bracket: Fasten the bracket to the first threaded hole and the third threaded hole with bolts; Applying adhesive to the gaps between the battery lower casing and the bracket, the battery lower casing and the explosion-proof valve, and the bracket and bolts using adhesive application equipment. The glue application equipment includes a flipping frame, a positioning plate, a flipping mechanism, a battery lower casing clamping mechanism, a robotic arm, and a glue application mechanism. The flipping mechanism is mounted on the flipping frame and is fixedly connected to the positioning plate. The battery lower casing clamping mechanism is mounted on the positioning plate and is used to fix the battery lower casing to the upper surface of the positioning plate. The flipping mechanism is used to drive the positioning plate and the battery lower casing to flip at a set angle. The robotic arm is located on one side of the flipping mechanism and is fixedly connected to the glue application mechanism. The robotic arm is used to drive the glue application mechanism to apply glue to the gaps between the battery lower casing and the bracket, the gaps between the battery lower casing and the explosion-proof valve, and the gaps between the bracket and the bolts. The battery lower casing clamping mechanism includes a first clamping assembly and a second clamping assembly. The first clamping assembly is located on one side of the explosion-proof valve, and the second clamping assembly is located in the rectangular through hole of the battery lower casing. The first clamping assembly includes a first clamping cylinder, a connecting rod, a pressure plate, a first pressure head, and a hinge seat. The output end of the first clamping cylinder is vertically upward, and the connecting rod is fixedly connected to the output end of the first clamping cylinder. The upper part of the connecting rod is hinged to the lower part of the pressure plate, and the upper part of the pressure plate is fixedly connected to the first pressure head. A hinge seat is disposed on the upper surface of the first pressing cylinder, and the hinge seat is hinged to the middle of the pressure plate. The lower surface of the first pressing head is used to abut against the upper surface of the lower battery casing. A positioning mechanism is disposed on the upper surface of the positioning plate. The positioning mechanism includes a plurality of first glue-applying anti-misalignment blocks disposed on the upper surface of the positioning plate. The first glue-applying anti-misalignment blocks are located on one side of the explosion-proof valve. A U-shaped clearance groove is opened on the upper part of the first glue-applying anti-misalignment block, and the first pressing cylinder is used to drive the first pressing head to move up and down in the clearance groove. The second clamping assembly includes a second clamping cylinder, a rotating arm, and a second pressure head. The second clamping cylinder is a rotating cylinder. The rotating arm is located on the output end of the second clamping cylinder. The end of the rotating arm is fixedly connected to the second pressure head. The lower surface of the second pressure head is used to abut against the upper surface of the lower battery housing.

2. The manufacturing process of the lower housing of the power battery according to claim 1, characterized in that, A first cleaning process is provided between the first machining and the second friction welding. The first cleaning process includes cleaning the sealing plate and cleaning the rear side of the lower battery casing.

3. The manufacturing process of the lower housing of the power battery according to claim 1, characterized in that, Between the fourth machining step and the installation of the water nozzle and explosion-proof valve, there is also a process for electrophoresis and spraying insulating powder on the lower battery casing.

4. The manufacturing process of the lower housing of the power battery according to claim 3, characterized in that, After the insulating powder spraying process, a second cleaning process is provided, which includes cleaning the battery lower casing using a through-type cleaning line.

5. The manufacturing process of the lower housing of the power battery according to claim 4, characterized in that, After the second cleaning process, there is also a process of affixing labels to the lower battery casing.

6. The manufacturing process of the lower housing of the power battery according to claim 1, characterized in that, An airtightness testing process is also provided between the water tap and the explosion-proof valve and the assembly bracket. The airtightness testing process includes leak testing of the inner cavity of the lower battery box and the cooling cavity of the lower battery box.

7. The manufacturing process of the lower housing of the power battery according to claim 1, characterized in that, After the die-cast blank is obtained, the entire surface of the blank needs to be polished and deburred.

8. The manufacturing process of the lower housing of the power battery according to claim 7, characterized in that, After the deburring is completed, the lower battery casing needs to be shot blasted.

9. A lower casing for a power battery, characterized in that, It is manufactured by the production process of the lower casing of the power battery as described in any one of claims 1-8.

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