Precise positioning and assembling tool method for air cooling plate and battery module

Abstract

The invention relates to the technical field of assembly of a battery module and an air cooling plate, in particular to a precise positioning and assembly tool method for the air cooling plate and the battery module. The method comprises the following steps: acquiring thermal expansion coefficient data of a battery module and an air cooling plate, analyzing thermal expansion blending capability of a buffer material, and selecting a proper buffer material; the design parameters of the flexible air cooling plate are analyzed, and the flexible air cooling plate is designed; carrying out automatic assembly and precise positioning on the buffer material and the flexible air cooling plate; and finally, thermal expansion stress is tested in real time, stress feedback data are obtained, and an automatic adjusting system is combined to dynamically adjust the assembly process. The problems of stress concentration and assembly deviation caused by thermal expansion difference can be effectively solved, and the assembly precision and the long-term stability of the system are improved.

Description

[0001] The present invention relates to the technical field of assembly of a battery module and an air cooling system, and in particular to a method for precise positioning and assembly of an air cooling plate and a battery module. Background Art

[0002] In application scenarios such as new energy vehicles and battery energy storage equipment, battery modules usually work together with air cooling plates to achieve effective thermal management. However, due to the different materials used in battery modules and air cooling plates, they have different thermal expansion coefficients when the temperature changes, resulting in thermal stress concentration, structural deformation, and assembly deviation during the assembly process. This stress concentration caused by the difference in thermal expansion of materials will not only affect the accuracy of assembly, but may also cause fatigue damage to components during long-term use, thereby affecting the heat dissipation performance and safety of the system.

[0003] Traditional assembly methods are difficult to effectively alleviate the thermal expansion differences between battery modules and air cooling plates, especially under extreme temperature conditions, which can easily lead to problems such as inaccurate assembly positions and uneven stress distribution. Therefore, how to rationally select buffer materials, design flexible structures to reconcile the thermal expansion differences of different materials, and combine automated assembly technology to improve assembly accuracy and system stability has become an urgent problem to be solved in this technical field. Summary of the invention

[0004] The present invention provides a method for precise positioning and assembly of air-cooled plates and battery modules, so as to solve the problem of how to ensure the assembly accuracy and long-term stability of the system at different temperatures by reasonably selecting buffer materials, designing flexible air-cooled plates and combining automated assembly and precise positioning systems when stress concentration and assembly deviation occur between the battery module and the air-cooled plate due to differences in material thermal expansion.

[0005] In order to solve the above technical problems, the present invention provides a method for precise positioning and assembly of an air cooling plate and a battery module, comprising: Obtain the thermal expansion coefficient data of the battery module and the air cooling plate, analyze the thermal expansion compensating capacity of the buffer material, and select the appropriate buffer material; Obtain the thermal cycle characteristics of the battery module and the air-cooling plate, analyze the design parameters of the flexible air-cooling plate, and determine the material, thickness, structural design, and deformable area of ​​the flexible air-cooling plate; Automatically assembling the buffer material and the flexible air-cooling plate, accurately positioning the battery module and the air-cooling plate based on the automated assembly equipment, and completing the assembly of the battery module and the air-cooling plate; Based on the assembled battery module and air-cooling plate combination, real-time thermal expansion stress testing is carried out to obtain stress feedback data, and the assembly process is dynamically adjusted based on the automated adjustment system.

[0006] Furthermore, the step of obtaining the thermal expansion coefficient data of the battery module and the air-cooling plate includes measuring the dimensional changes of the battery module and the air-cooling plate under different temperature conditions in real time through a sensor, and generating thermal expansion curves of the battery module and the air-cooling plate.

[0007] Furthermore, the buffer material selection step includes analyzing the thermal expansion coefficients of different materials, comparing the thermal expansion difference between the battery module and the air-cooling plate, and selecting a buffer material that can reconcile the thermal expansion difference between the two.

[0008] Furthermore, the step of analyzing the design parameters of the flexible air-cooling plate includes determining the material thickness, structural design, cross-sectional area and distribution of the deformable region of the flexible air-cooling plate according to the thermal cycle characteristics of the battery module and the air-cooling plate.

[0009] Furthermore, the automated assembly step includes installing the buffer material using automated assembly equipment, and adjusting the equipment operation path so that the buffer material and the flexible air-cooling plate maintain precise docking during the assembly process.

[0010] Furthermore, the precise positioning step includes using machine vision and laser positioning systems to capture three-dimensional coordinate information of the battery module and the air-cooling plate to ensure position accuracy during the assembly process.

[0011] Furthermore, the thermal expansion stress real-time testing step includes simulating the temperature change of the battery module and the air-cooling plate in the working environment, and recording the stress distribution generated during the thermal expansion process.

[0012] Furthermore, the stress feedback data includes the maximum stress value, stress variation range and stress distribution curve of the battery module and air-cooling plate assembly under various temperature conditions.

[0013] Furthermore, based on the stress feedback data, the automatic adjustment system dynamically adjusts the assembly process by adjusting the position of the buffer material and the deformable area of ​​the flexible air-cooling plate.

[0014] Furthermore, the automatic adjustment system optimizes the assembly path of the buffer material and the flexible air-cooling plate during the dynamic adjustment process to ensure uniform stress distribution of the battery module and the air-cooling plate under actual operating conditions.

[0015] The key innovative features of the present invention include: (1) Thermal expansion coordination design of buffer materials: Buffer materials are selected based on the thermal expansion coefficients of the battery module and the air-cooling plate to effectively coordinate the expansion difference between the two and reduce stress concentration problems.

[0016] (2) Design of flexible air-cooling plate: Through flexible structural design and the layout of deformable areas, the assembly error between the battery module and the air-cooling plate is further reduced to ensure stress balance during thermal cycles.

[0017] (3) Automated assembly and precision positioning: Utilize automated assembly equipment and machine vision systems to achieve high-precision assembly, significantly reduce human errors in the assembly process, and improve system consistency and efficiency.

[0018] (4) Real-time testing and dynamic adjustment of thermal expansion stress: By obtaining stress feedback data in real time and dynamically adjusting the assembly process based on this, the uniformity of stress distribution and the long-term stability of the system under different temperature conditions can be ensured.

[0019] The following are its main beneficial effects: The present invention solves the problems of stress concentration and assembly deviation caused by thermal expansion differences by collecting and analyzing data on the thermal expansion coefficients of battery modules and air-cooled plates, rationally selecting buffer materials, and designing flexible air-cooled plate structures. Precision positioning is achieved through automated assembly equipment to ensure high precision and consistency of component assembly. Further combined with real-time testing of thermal expansion stress and stress feedback data, the system can dynamically adjust assembly parameters, optimize the assembly process, and ultimately improve the long-term stability and reliability of the assembly under complex temperature change conditions. Compared with traditional manual or simple assembly processes, the present invention adopts a buffer material blending method based on thermal expansion coefficient data, which can significantly reduce stress concentration, and further alleviate structural deformation through the design of a flexible air-cooled plate. The combination of real-time monitoring of thermal expansion stress and an automated adjustment system ensures uniform stress distribution during the assembly process and avoids component fatigue damage caused by temperature changes. This dynamic adjustment function improves assembly accuracy and extends the service life of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A schematic diagram of a process for a precise positioning and assembly tooling method of an air cooling plate and a battery module provided in an embodiment of the present application; Figure 2 A structural block diagram of a method for precise positioning and assembly of an air cooling plate and a battery module provided in an embodiment of the present application; DETAILED DESCRIPTION

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by technicians in the technical field of the present application; the terms used in the specification of the application herein are only for the purpose of describing specific embodiments and are not intended to limit the present application; the terms "including" and "having" and any variations thereof in the specification and claims of the present application and the above-mentioned drawings are intended to cover non-exclusive inclusions. The terms "first", "second", etc. in the specification and claims of the present application or the above-mentioned drawings are used to distinguish different objects, not to describe a specific order.

[0022] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0023] Embodiment 1: Reference Figure 1 , is a flow chart of a method for precise positioning and assembly of an air cooling plate and a battery module provided by an embodiment of the present invention, the process may at least include steps S100-S400: S100, obtaining thermal expansion coefficient data of the battery module and the air-cooling plate, analyzing the thermal expansion compensating capacity of the buffer material, and obtaining a suitable buffer material; S200, analyzing the design parameters of the flexible air-cooling plate from the thermal cycle characteristics of the battery module and the air-cooling plate to obtain a design scheme of the flexible air-cooling plate; S300, performing an automated assembly process on the buffer material and the flexible air-cooling plate design, performing precise positioning and assembly based on automated assembly equipment, and generating an assembled battery module and air-cooling plate assembly; S400, based on the assembled assembly, perform real-time thermal expansion stress testing to obtain stress feedback data, and dynamically adjust the assembly process in combination with an automated adjustment system.

[0024] Step S100 at least includes steps S110-S130: S110: Obtain thermal expansion coefficient data of materials used for the battery module and the air cooling plate, and generate respective thermal expansion curves.

[0025] First, obtain the thermal expansion coefficient data of the battery module and the air cooling plate. The thermal expansion coefficient is defined as the linear expansion rate of the material, usually using the formula:

[0026] Where α is the thermal expansion coefficient of the material, For materials that change in temperature The length change under is the initial length of the material. The battery module and the air cooling plate are measured at different operating temperature ranges to obtain their dimensional change values ​​when the temperature changes.

[0027] Through multiple temperature cycles, the expansion data of the battery module and the air cooling plate are measured respectively to generate the corresponding thermal expansion curve. In this step, the input data of the battery module includes its material properties (such as aluminum alloy, steel, etc.), and the temperature range is usually [ , ], Represents the lowest temperature in the working environment. is the highest temperature during operation. Similarly, the expansion data of the air cooling plate is generated based on its material properties. Finally, the obtained thermal expansion curve of the battery module is recorded as (T), the thermal expansion curve of the air-cooled plate is recorded as (T), they represent the size change trends under temperature changes.

[0028] S120: Based on the acquired thermal expansion coefficient data, thermal expansion compatibility analysis of the buffer material is performed.

[0029] Furthermore, based on the thermal expansion curves of the battery module and the air cooling plate obtained (T) and (T), analyze the thermal expansion compatibility of the buffer material. The compatibility is determined by selecting the buffer material. (T), so that it is in [ , ] The thermal expansion coefficient in the range is close to or moderately between the battery module and the air cooling plate.

[0030] The formula for calculating the blending capacity is:

[0031] in, It is the difference in thermal expansion between the buffer material, the battery module and the air cooling plate. The smaller the coefficient of thermal expansion, the better the cushioning material can accommodate the difference in thermal expansion between the two. By gradually comparing the thermal expansion coefficient curves of different cushioning materials, the material candidate that can minimize the difference in thermal expansion between the two is determined.

[0032] S130: Based on the analysis results, a material that can accommodate the difference in thermal expansion between the battery module and the air cooling plate is selected from a variety of buffer materials to obtain a suitable buffer material, and its characteristic parameters are recorded.

[0033] Combined with the above-mentioned results of the harmonic capacity analysis, a buffer material suitable for the battery module and the air cooling plate is further selected from a variety of candidate buffer materials. The specific selection basis is the harmonic coefficient The minimum value of the thermal expansion coefficient, as well as other properties of the buffer material within the operating temperature range (such as mechanical strength, durability, etc.). After the buffer material is selected, its characteristic parameters are recorded, including the thermal expansion coefficient. (T), material elastic modulus And its fatigue performance under actual working conditions. The obtained buffer material parameters will be used in the subsequent assembly and design stages. The final buffer material parameters (T) will directly serve as a reference for the subsequent design parameters of the flexible air-cooling plate to ensure that the collaborative work between the buffer material and the flexible air-cooling plate can alleviate the stress concentration problem caused by thermal expansion to the greatest extent.

[0034] The buffer material parameters (such as (T) ) will be directly used in the design of flexible air cooling plates in subsequent S200 modules. In S220, the design of flexible air cooling plates needs to be combined with the thermal expansion parameters of buffer materials to ensure that the designed flexible structure can effectively adapt to the thermal expansion behavior of the entire system, thereby ensuring the stability of the entire battery module and air cooling plate assembly system under different temperature conditions.

[0035] Step S200 at least includes steps S210-S230: S210: Obtain thermal cycle characteristics of the battery module and the air cooling plate according to their working environment.

[0036] Based on the working environment of the battery module and the air cooling plate, the thermal cycle characteristic data is obtained. The thermal cycle characteristics include the temperature change range [ , ], heat load Q(T) in each temperature range, heat conduction efficiency λ(T) and other parameters.

[0037] Among them, the temperature variation range of the battery module and the air cooling plate is [ , ] is determined according to its working environment and usage scenario. The thermal load of the battery module (T) and the heat load of the air-cooled plate (T) is obtained through heat conduction analysis, heat conduction efficiency (T) and (T) is determined by the thermal conductivity of the material. By measuring the thermal cycle at different temperatures multiple times and recording the changes in the heat load of both when the temperature changes, the key data indicators of the battery module and the air cooling plate under the thermal cycle conditions are obtained. After obtaining these data, the buffer material parameters selected in S130 are further used. (T), the thermal expansion characteristics of the buffer material during temperature changes are correlated with the thermal cycle characteristics of the battery module and the air-cooling plate to ensure that the thermal expansion coordination design is consistent with the structural parameter calculation of the flexible air-cooling plate.

[0038] S220: Parameter design of flexible air-cooling plate based on the thermal cycle characteristics of battery module and air-cooling plate.

[0039] Furthermore, based on the obtained thermal cycle characteristics of the battery module and the air cooling plate, the design parameter analysis of the flexible air cooling plate is performed. Specifically, firstly, the thermal expansion curves of the battery module and the air cooling plate are combined. (T) and (T), determine the thermal expansion during thermal cycling (T) and (T), where:

[0040] On this basis, the stress distribution of the flexible air-cooled plate under different temperature conditions is analyzed and the required material thickness is calculated. , flexible zone length , and geometric design parameters. The design of the flexible air cooling plate must meet the requirements in various temperature ranges (especially [ , ]) can flexibly adjust the deformation and be consistent with the thermal expansion coordination ability of the cushioning material.

[0041] Furthermore, the elastic modulus of the buffer material , the stress distribution of the flexible air-cooled plate under stress is determined by the stress analysis equation:

[0042] in, is the stress of the flexible air-cooled plate during temperature change, F is the force caused by thermal expansion, is the cross-sectional area of ​​the flexible air-cooling plate, is the length change of the flexible air-cooled plate during thermal expansion.

[0043] Through the above calculations, the key design parameters of the flexible air cooling plate, such as material thickness, are determined. , cross-sectional area , and stress distribution law .

[0044] S230: Combining the analysis results, a complete design scheme for the flexible air cooling plate is formed.

[0045] The material selection of the flexible air-cooling plate, combined with the buffer material parameters in S130, ensures that the material has sufficient elasticity and thermal expansion coordination ability within the operating temperature range. The geometric structure design of the flexible air-cooling plate determines the specific distribution of the deformable area and the thickness adjustment range to ensure that the air-cooling plate can adapt to thermal expansion changes during the entire thermal cycle. The length, thickness and cross-sectional area planning of each flexible zone included in the structural design ensure the overall stability and flexibility of the flexible air-cooling plate. The designed flexible air-cooling plate must meet the stress and dimensional change requirements generated by the battery module and the air-cooling plate during the thermal expansion process, while taking into account the convenience of assembly in actual working conditions.

[0046] Step S300 at least includes steps S310-S330: S310: Assemble the selected buffer material and the designed flexible air cooling plate through automated equipment.

[0047] Specifically, based on the buffer material obtained in S130 (T) and the design parameters of the flexible air-cooling plate formed in S230, the assembly process is performed using automated assembly equipment. The automated assembly equipment should be dynamically adjusted according to the thermal expansion and reconciliation capacity of the buffer material and the material properties of the flexible air-cooling plate.

[0048] The location of the buffer material should take into account the thermal expansion behavior of the battery module and the air cooling plate to ensure that the buffer material can be evenly distributed between the two and provide sufficient elastic space. The assembly of the flexible air cooling plate needs to be based on its deformable area. The design enables the flexible structure to effectively cover areas with large thermal expansion. During the assembly process, the automated equipment will adjust the geometry according to the input geometric parameters (such as the thickness of the flexible air cooling plate). and cross-sectional area ) automatically adjusts the operation path of the robotic arm to ensure the accuracy of the assembly position of each part. Furthermore, the assembly equipment completes the preliminary docking of the buffer material and the flexible air-cooling plate, providing a basis for the next step of precise positioning.

[0049] S320: Use an automated positioning system to precisely position the battery module and air cooling plate.

[0050] Furthermore, during the assembly process, an automated precision positioning system is used for fine-tuning. Specifically, machine vision and laser positioning technology are used to monitor the relative position between the battery module and the air cooling plate in real time. This step ensures that the thermal expansion harmonic coefficient of the buffer material obtained in S130 is Stress distribution of flexible air cooling plate in S220 It can fully play its role in the assembly process to avoid position deviation or stress concentration.

[0051] The relative position of the battery module and the air-cooling plate is captured by the visual sensor, and the captured three-dimensional coordinate information is transmitted to the automatic control system. The system corrects the movement path of the robot arm in real time. The automatic positioning system combines the blending ability of the buffer material to ensure that the connection position between the air-cooling plate and the battery module is in the optimal stress distribution area to avoid local excessive force causing structural deformation or loosening. During the positioning process, the impact of temperature changes on components must also be considered. The assembly equipment will [ , ] to ensure that the assembly remains precisely docked under extreme temperatures.

[0052] S330: Generate an assembled battery module and air cooling plate assembly.

[0053] After completing the automated assembly and precise positioning of the components, the final battery module and air cooling plate assembly is generated. The buffer material has been installed between the battery module and the air cooling plate, and its elasticity and thermal expansion compatibility (T) has ensured that the size difference between the two is smoothly transitioned. Deformable area of ​​the flexible air cooling plate It is precisely positioned and can flexibly adjust deformation according to the thermal cycle behavior of the battery module and the air cooling plate to reduce stress concentration. The final assembly position of all components is kept within the error range through the combined action of machine vision and automated positioning systems. The resulting assembly will then enter the subsequent thermal expansion stress test phase (S400) to verify the long-term stability of the assembly and provide data support for future dynamic adjustments. Step S400 at least includes steps S410-S430: S410: Perform a thermal expansion stress test on the assembled battery module and air-cooling plate assembly to simulate the temperature changes under actual operating conditions and monitor the stress distribution generated during the thermal expansion process in real time.

[0054] Specifically, in this step, the battery module and air cooling plate assembly generated based on S330 is subjected to a thermal expansion stress test, and the stress distribution generated during the thermal expansion process is monitored in real time by simulating the temperature change under actual working conditions.

[0055] The assembled assembly is in the temperature range [ , ] to simulate thermal cycles. We use sensors to measure stress in different parts of the and Changes ensure that these stresses are within the controllable range of the buffer material and the flexible air cooling plate. Use stress sensors to capture the stress distribution at each key position and record the stress distribution curves at different temperature points. (T) to assess the responsiveness of the system.

[0056]

[0057] in, (T) is the stress at temperature T, is the elastic modulus of the material, is the length change caused by temperature change, is the original length.

[0058] S420: Record changes in thermal expansion stress and generate corresponding stress feedback data.

[0059] During the real-time test, the changes in thermal expansion stress are recorded and stress feedback data is generated. Specifically, based on the collected temperature and stress change curves (T), conduct a detailed analysis of the stress distribution of the assembly at different temperatures and identify high stress areas and locations where stress concentration may occur.

[0060] Stress feedback data mainly includes the following information: : Maximum stress value in the assembly; (T): the magnitude of stress change caused by temperature change; :Stress positions close to the material yield strength identify potential stress failure points. These data are used as a reference for subsequent adjustments to ensure that the assembly maintains good structural stability under extreme temperature conditions. In particular, if there are excessively large stress concentration areas or high stress points , we need to focus on the stress changes in these areas.

[0061] S430: According to the acquired stress feedback data, the automatic adjustment system dynamically adjusts the assembly process.

[0062] According to the stress feedback data obtained by S420, combined with the automated adjustment system, the assembly process is dynamically adjusted. In this step, the automated system will adjust various parameters in the assembly through data feedback to ensure that the stress distribution of the assembly is more uniform. Specifically, the automated adjustment system is adjusted in the following ways: Adjust the position or thickness of the buffer material to optimize its effect of reconciling thermal expansion differences and ensure that the buffer material can fully disperse the stress concentration area. In the high stress area, the flexible air cooling plate can be deformed to the deformable area. Re-optimize to better adapt to thermal expansion behavior under different temperature conditions. Adjust the local thickness of the plate according to the stress feedback curve or length , ensuring that the flexible board can effectively alleviate stress concentration. The formula for automatic adjustment is:

[0063] in, is the change in assembly parameters that need to be adjusted, (T) is the stress distribution monitored in real time, (T) is the deformation of the flexible air-cooled plate at different temperatures.

[0064] The key innovative features of the present invention include: (1) Thermal expansion coordination design of buffer materials: Buffer materials are selected based on the thermal expansion coefficients of the battery module and the air-cooling plate to effectively coordinate the expansion difference between the two and reduce stress concentration problems.

[0065] (2) Design of flexible air-cooling plate: Through flexible structural design and the layout of deformable areas, the assembly error between the battery module and the air-cooling plate is further reduced to ensure stress balance during thermal cycles.

[0066] (3) Automated assembly and precision positioning: Utilize automated assembly equipment and machine vision systems to achieve high-precision assembly, significantly reduce human errors in the assembly process, and improve system consistency and efficiency.

[0067] (4) Real-time testing and dynamic adjustment of thermal expansion stress: By obtaining stress feedback data in real time and dynamically adjusting the assembly process based on this, the uniformity of stress distribution and the long-term stability of the system under different temperature conditions can be ensured.

[0068] The following are its main beneficial effects: The present invention collects and analyzes the thermal expansion coefficients of the battery module and the air-cooled plate, rationally selects buffer materials, and designs a flexible air-cooled plate structure to solve the stress concentration and assembly deviation problems caused by thermal expansion differences. Precision positioning is achieved through automated assembly equipment to ensure high accuracy and consistency of component assembly. Further combined with real-time testing of thermal expansion stress and stress feedback data, the system can dynamically adjust assembly parameters, optimize the assembly process, and ultimately improve the long-term stability and reliability of the assembly under complex temperature change conditions.

[0069] Compared with traditional manual or simple assembly processes, the present invention adopts a buffer material blending method based on thermal expansion coefficient data, which can significantly reduce stress concentration, and further alleviate structural deformation through the design of flexible air-cooled plates. The combination of real-time monitoring of thermal expansion stress and an automated adjustment system ensures uniform stress distribution during assembly and avoids component fatigue damage caused by temperature changes. This dynamic adjustment function improves assembly accuracy and extends the service life of the equipment.

[0070] Embodiment 2: Figure 2The structure block diagram of a method for precise positioning and assembly of an air cooling plate and a battery module according to an embodiment of the present invention is shown. Figure 2 As shown, the structure may include: The thermal expansion data acquisition module 10 is used to obtain the thermal expansion coefficient data of the battery module and the air-cooling plate, and analyze the dimensional changes with temperature. Through high-precision sensors and measuring equipment, the expansion behavior of the two in different temperature ranges is recorded in real time, and the thermal expansion curves of the battery module and the air-cooling plate are generated.

[0071] Collect material property data of battery modules and air cooling plates, including their operating temperature range, expansion characteristics, etc. Through temperature cycle testing, the thermal expansion coefficients of both at various temperature points are captured to form a thermal expansion curve; Output thermal expansion coefficient data to provide input for subsequent buffer material selection and flexible air cooling plate design.

[0072] The buffer material analysis module 20 analyzes and selects a buffer material that can reconcile the difference in thermal expansion between the battery module and the air-cooling plate based on the thermal expansion data of the battery module and the air-cooling plate.

[0073] By simulating the stress and deformation behavior of the buffer material during temperature changes, it is ensured that it can smoothly reconcile the expansion difference between the battery module and the air cooling plate.

[0074] Analyze the thermal expansion compatibility of different buffer materials and calculate their compatibility coefficients; Select the most suitable cushioning material through the thermal expansion difference calculation formula and record its characteristic parameters (such as elastic modulus, fatigue performance, etc.); Output buffer material parameters for subsequent flexible air cooling plate design and assembly stages.

[0075] The automatic assembly and precision positioning module 30 is responsible for the automatic assembly of the buffer material and the flexible air cooling plate to ensure the precise positioning between the battery module and the air cooling plate. The mechanical control is carried out by automatic equipment, combined with machine vision and laser positioning system to ensure the precise position of each component.

[0076] Automatically install buffer materials and dynamically adjust the assembly path according to their characteristics; The precision positioning system captures the three-dimensional coordinate information of the assembly through sensors and adjusts the assembly process in real time to ensure error-free; Finally, the battery module and air cooling plate are assembled and ready for subsequent testing.

[0077] The stress real-time testing and dynamic adjustment module 40 is used to perform real-time testing of the thermal expansion stress of the assembled assembly, and dynamically adjust the assembly process through the automatic adjustment system according to the stress feedback data. During the test, the temperature changes in the actual operating environment are simulated to monitor and analyze the stress distribution of the assembly.

[0078] Use stress sensors to monitor stress changes in different areas in real time and generate stress feedback data; Combine stress data with the feedback system to dynamically adjust the assembly process and optimize the assembly accuracy of the buffer material and the flexible air-cooling plate; Through the dynamic adjustment system, the stress distribution of the assembly under actual operating conditions is ensured to be uniform, thereby improving long-term stability.

[0079] The beneficial effects of this embodiment The invention solves the stress concentration problem caused by the difference in thermal expansion between the battery module and the air-cooling plate by rationally selecting the design of buffer materials and flexible air-cooling plates. Its automated assembly and precision positioning modules ensure high-precision assembly of components, effectively reducing structural deformation and assembly errors caused by thermal expansion. In addition, the real-time stress testing and dynamic adjustment system continuously monitors the stress changes of the assembly under actual operating conditions, and adjusts the assembly process in a timely manner to ensure the long-term stability and reliability of the system.

[0080] Obviously, the embodiments described above are only some embodiments of the present application, rather than all embodiments. The preferred embodiments of the present application are given in the accompanying drawings, but they do not limit the patent scope of the present application. The present application can be implemented in many different forms. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present application more thorough and comprehensive. Although the present application is described in detail with reference to the aforementioned embodiments, for those skilled in the art, it is still possible to modify the technical solutions recorded in the aforementioned specific implementation methods, or to perform equivalent replacement of some of the technical features therein. Any equivalent structure made using the contents of the specification and drawings of this application, directly or indirectly used in other related technical fields, is similarly within the scope of patent protection of this application.

Claims

1. A method for precise positioning and assembly of air cooling plates and battery modules, characterized in that: The following steps are involved: Obtain the thermal expansion coefficient data of the battery module and the air cooling plate, analyze the thermal expansion compensating capacity of the buffer material, and select the appropriate buffer material; Obtain the thermal cycle characteristics of the battery module and the air-cooling plate, analyze the design parameters of the flexible air-cooling plate, and determine the material, thickness, structural design, and deformable area of ​​the flexible air-cooling plate; Automatically assembling the buffer material and the flexible air-cooling plate, accurately positioning the battery module and the air-cooling plate based on the automated assembly equipment, and completing the assembly of the battery module and the air-cooling plate; Based on the assembled battery module and air-cooling plate combination, real-time thermal expansion stress testing is carried out to obtain stress feedback data, and the assembly process is dynamically adjusted based on the automated adjustment system.

2. The tooling method according to claim 1, characterized in that: The step of obtaining the thermal expansion coefficient data of the battery module and the air-cooling plate includes measuring the dimensional changes of the battery module and the air-cooling plate under different temperature conditions in real time through sensors, and generating thermal expansion curves of the battery module and the air-cooling plate.

3. The tooling method according to claim 1, characterized in that: The step of selecting the buffer material includes analyzing the thermal expansion coefficients of different materials, comparing the thermal expansion difference between the battery module and the air-cooling plate, and selecting a buffer material that can reconcile the thermal expansion difference between the two.

4. The tooling method according to claim 1, characterized in that: The step of analyzing the design parameters of the flexible air-cooling plate includes determining the material thickness, structural design, cross-sectional area, and distribution of the deformable area of ​​the flexible air-cooling plate according to the thermal cycle characteristics of the battery module and the air-cooling plate.

5. The tooling method according to claim 1, characterized in that: The automated assembly step includes installing the buffer material using automated assembly equipment and adjusting the equipment operation path so that the buffer material and the flexible air-cooled plate maintain precise docking during the assembly process.

6. The tooling method according to claim 1, characterized in that: The precise positioning step includes using machine vision and laser positioning systems to capture the three-dimensional coordinate information of the battery module and the air-cooling plate to ensure the position accuracy during the assembly process.

7. The tooling method according to claim 1, characterized in that: The real-time thermal expansion stress testing step includes simulating the temperature changes of the battery module and the air-cooling plate in the working environment, and recording the stress distribution generated during the thermal expansion process.

8. The tooling method according to claim 1, characterized in that: The stress feedback data includes the maximum stress value, stress variation range and stress distribution curve of the battery module and air-cooling plate assembly under various temperature conditions.

9. The tooling method according to claim 1, characterized in that: Based on the stress feedback data, the automated adjustment system dynamically adjusts the assembly process by adjusting the position of the buffer material and the deformable area of ​​the flexible air-cooling plate.

10. The tooling method according to claim 1, characterized in that: The automatic adjustment system optimizes the assembly path of the buffer material and the flexible air-cooling plate during the dynamic adjustment process, ensuring uniform stress distribution of the battery module and the air-cooling plate under actual operating conditions.

Images