A method for assembling a long-size high-weight battery module

Abstract

The application discloses a kind of assembly methods of long size high weight battery module, the present application relates to the assembly field of battery module, S1: preparation assembly fixture body;S2: battery unit screening and pairing;S3: battery unit stacking and fixing;S4: the electrical connection of battery module body;S5: the thermal management of battery module body.The assembly method of long size high weight battery module described in the application, by screening and pairing to battery unit, can ensure that battery module can work stably and efficiently in the process of use, can avoid that battery module body appears contact badly, power loss, the inconsistency of charge and discharge, can ensure that the power loss of each battery unit is more consistent in the long-term storage and use process of battery module, by the assembly fixture body of setting, can be adjusted according to the use demand to its internal space, can adapt long size and high weight battery module body, so that the assembly range of assembly fixture body can be guaranteed.

Description

Technical Field

[0001] This invention relates to the field of battery module assembly, and particularly to a method for assembling a long, heavy battery module. Background Technology

[0002] A battery module is a battery assembly consisting of multiple battery cells connected together in series, parallel, or series-parallel combination. It is an intermediate unit between a single battery cell and a complete battery system.

[0003] There is a lack of good assembly methods for long and heavy battery modules. In addition, long and heavy battery modules require more battery cells to be assembled together. Different battery cells cannot be well adapted, which will affect the performance of the assembled battery module.

[0004] Therefore, it is necessary to propose an assembly method for long and heavy battery modules to solve the above problems. Summary of the Invention

[0005] The main objective of this invention is to provide an assembly method for a long and heavy battery module, which can effectively solve the problems in the background art.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] An assembly method for a long and heavy battery module includes the following steps:

[0008] S1: Prepare to assemble the fixture body. Bearing seats are symmetrically installed at both ends of the top of the fixture body. A two-way lead screw is installed on one side of the two bearing seats opposite to each other. A drive motor is installed on the outer wall of the fixture body. The drive motor is connected to the two-way lead screw through a drive shaft.

[0009] The top two ends of the assembly fixture body are symmetrically and movably connected with clamping plates, and the bottom of the two clamping plates are symmetrically installed with assembly seats on opposite sides. The center of the bottom of the assembly seat is threaded to the outer wall of the bidirectional lead screw.

[0010] The top of the assembly fixture body is equipped with a guide rail, the bottom of the assembly base is movably connected to the outer wall of the guide rail, a linear motor is installed in the inner cavity of one end of the clamping plate, and a connecting frame is installed at the drive end of the linear motor.

[0011] S2: Battery cell screening and matching. High-precision testing equipment is used to screen and match battery cells to ensure that the performance and capacity of the battery cells are consistent.

[0012] S3: Battery cell stacking and fixing: The selected and matched battery cells are stacked together according to the design requirements, and they are fixed in the module frame by the assembly fixture body to form the battery module body.

[0013] S4: Electrical connection of the battery module body, prepare the connecting parts of the battery unit, clean and pre-treat the welding surface of the connecting parts of the battery unit to remove oil and oxides, place the battery unit according to the design requirements, adjust the parameters of the laser welding equipment so that the laser beam accurately irradiates the connection part for welding, and after the welding is completed, check the welding quality, including appearance inspection and electrical performance testing.

[0014] S5: Thermal management of the battery module body. A heat dissipation device is installed to manage the thermal performance of the battery module body, thereby completing the assembly of the battery module body.

[0015] Preferably, there are four sets of guide rails, and the two sides of the bottom of the two mounting bases are movably connected to the outer walls of the four sets of guide rails.

[0016] Preferably, in step S2, the battery cell screening and pairing specifically includes the following steps:

[0017] S201: Capacity test, using a high-precision battery charge and discharge tester to accurately control the charging and discharging current and voltage, and record relevant data. At the same time, multiple battery cells are tested, and battery cells with capacity differences controlled within ±2% are paired together.

[0018] S202: Internal resistance test, using a battery internal resistance tester, battery cells with an internal resistance difference within ±10% are paired together;

[0019] S203: Open circuit voltage test. A high-precision voltmeter is used to measure the open circuit voltage of the battery. Battery cells with an open circuit voltage difference within ±50mV are paired.

[0020] S204: Self-discharge rate test. A constant temperature chamber is used to control the test environment temperature, and a high-precision voltmeter is used to measure the voltage. Battery cells with self-discharge rate differences controlled within ±0.1% are selected for pairing.

[0021] S205: Dynamic performance test, which uses a battery test system that can simulate different charge and discharge rates, and a temperature sensor to monitor the temperature change of the battery cells during the charge and discharge process. Based on the results of the dynamic performance test, battery cells with similar performance under simulated actual working conditions will be paired together.

[0022] Preferably, in step S3, the stacking and fixing of battery cells specifically includes the following steps:

[0023] S301: Prepare the frame and place it on top of the assembly fixture body. Connect it to one end of the frame through the connecting bracket. Start the drive motor to drive the double-acting screw to rotate, so that the bottom of the assembly base can be threaded into the double-acting screw. At this time, the clamping plates at both ends can be moved to the opposite side to clamp the frame.

[0024] S302: Start the linear motor, which drives the frame to move through the connecting frame. The selected and matched battery cells are then stacked together according to the design requirements. After stacking, they are installed in the inner cavity of the frame to form the battery module body.

[0025] Preferably, step S4 further includes the connection of conductive adhesive and flexible circuit board, wherein the connection of conductive adhesive is as follows: Select conductive adhesive, match it according to the material and working environment of battery connection components, apply conductive adhesive evenly to the connection part, then attach the battery unit and connection components together according to the design requirements, cure according to the curing requirements of conductive adhesive, and after curing, check the firmness and electrical performance of the connection.

[0026] Connection of flexible circuit boards: Design the circuit layout of the flexible circuit board to meet the electrical connection requirements of the battery module body. Connect the flexible circuit board to the battery tabs by soldering. After the connection is completed, check the connection quality of the flexible circuit board, including the continuity of the circuit, whether there is a short circuit, whether the installation position of the flexible circuit board in the battery module body is correct, and whether it will be squeezed or rubbed.

[0027] Preferably, in step S5, the thermal management of the battery module body specifically includes the following steps:

[0028] S501: Design the layout of the water cooling pipes, closely attach the water cooling pipes to the heat-generating parts of the battery module body, install a water pump in the water cooling pipes to drive the coolant circulation, and configure a heat exchanger, temperature sensor and control system to adjust the water pump flow and the working status of the heat exchanger according to the temperature of the battery module.

[0029] S502: The phase change material is encapsulated in a container, and then the container is installed inside the battery module body. During the installation process, it is necessary to ensure good thermal contact between the phase change material and the battery module.

[0030] Compared with the prior art, the present invention provides an assembly method for a long and heavy battery module, which has the following advantages:

[0031] This assembly method for long, heavy battery modules ensures stable and efficient operation during actual use by screening and matching battery cells. It avoids poor contact, power loss, and inconsistent charging and discharging during operation, and ensures that the power loss of each battery cell is relatively consistent during long-term storage and use. The assembly fixture body allows for adjustment of its internal space according to usage requirements during battery module assembly, thus accommodating battery modules of various sizes, including long and heavy ones, ensuring the assembly range of the fixture body is guaranteed. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the assembled structure of the present invention;

[0033] Figure 2 This is a schematic diagram of the assembly fixture body of the present invention.

[0034] In the diagram: 1. Assembly fixture body; 2. Support column; 3. Bearing seat; 4. Two-way lead screw; 5. Drive motor; 6. Guide rail; 7. Assembly seat; 8. Clamping plate; 9. Linear motor; 10. Connecting frame; 11. Battery module body. Detailed Implementation

[0035] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0036] like Figure 1-2 As shown, an assembly method for a long and heavy battery module includes the following steps:

[0037] S1: Prepare to assemble the fixture body 1. Bearing seats 3 are symmetrically installed at both ends of the top of the fixture body 1. A double-acting lead screw 4 is installed on the opposite side of the two bearing seats 3. A drive motor is installed on the outer wall of the fixture body 1. The drive motor is connected to the double-acting lead screw 4 through a drive shaft.

[0038] The two ends of the top of the assembly fixture body 1 are symmetrically connected with clamping plates 8. The bottom of the two clamping plates 8 on opposite sides is symmetrically installed with assembly seats 7. The center of the bottom of the assembly seat 7 is threaded to the outer wall of the double-acting screw 4.

[0039] The top of the assembly fixture body 1 is equipped with a guide rail 6. There are four sets of guide rails 6. The two sides of the bottom of the two assembly seats 7 are movably connected to the outer wall of the four sets of guide rails 6. The bottom of the assembly seat 7 is movably connected to the outer wall of the guide rail 6. A linear motor 9 is installed in the inner cavity of one end clamping plate 8. A connecting frame 10 is installed at the drive end of the linear motor 9.

[0040] S2: Battery cell screening and pairing. High-precision testing equipment is used to screen and pair battery cells to ensure consistent performance and capacity. This includes the following steps:

[0041] S201: Capacity test, using a high-precision battery charge and discharge tester to accurately control the charging and discharging current and voltage, and record relevant data. At the same time, multiple battery cells are tested, and battery cells with capacity differences controlled within ±2% are paired together.

[0042] S202: Internal resistance test, using a battery internal resistance tester, battery cells with an internal resistance difference within ±10% are paired together;

[0043] S203: Open circuit voltage test. A high-precision voltmeter is used to measure the open circuit voltage of the battery. Battery cells with an open circuit voltage difference within ±50mV are paired.

[0044] S204: Self-discharge rate test. A constant temperature chamber is used to control the test environment temperature, and a high-precision voltmeter is used to measure the voltage. Battery cells with self-discharge rate differences controlled within ±0.1% are selected for pairing.

[0045] S205: Dynamic performance test, which uses a battery test system that can simulate different charge and discharge rates, and a temperature sensor to monitor the temperature change of the battery cell during the charge and discharge process. Based on the results of the dynamic performance test, battery cells with similar performance under simulated actual working conditions will be paired together.

[0046] S3: Battery cell stacking and fixing. The selected and matched battery cells are stacked together according to design requirements, and fixed in the module frame by the assembly fixture body 1, thereby forming the battery module body 11. The specific operation steps include the following:

[0047] S301: Prepare the frame and place it on top of the assembly fixture body 1. Connect it to one end of the frame through the connecting bracket 10. Start the drive motor 5 to drive the double-acting screw 4 to rotate, so that the bottom of the assembly base 7 can be threadedly connected to the double-acting screw 4. At this time, the clamping plates 8 at both ends can be moved to the opposite side to clamp the frame.

[0048] S302: Start the linear motor 9, which drives the frame to move through the connecting frame 10. The selected and matched battery cells can be stacked together according to the design requirements. After stacking, they are installed in the inner cavity of the frame to form the battery module body 11.

[0049] S4: Electrical connection of battery module body 11, prepare the connecting parts of battery unit, clean and pre-treat the welding surface of battery unit connecting parts to remove oil and oxides, place the battery unit according to the design requirements, adjust the parameters of laser welding equipment so that the laser beam accurately irradiates the connecting parts for welding, and after welding is completed, inspect the welding quality, including appearance inspection and electrical performance testing.

[0050] It also includes the connection of conductive adhesive and flexible circuit board. The connection of conductive adhesive is as follows: Select conductive adhesive and match it according to the material and working environment of the battery connection component. Apply the conductive adhesive evenly to the connection part. Then attach the battery unit and connection component together according to the design requirements. Cure according to the curing requirements of the conductive adhesive. After curing, check the firmness and electrical performance of the connection.

[0051] Connection of flexible circuit boards: Design the circuit layout of the flexible circuit board to meet the electrical connection requirements of the battery module body 11. Connect the flexible circuit board to the battery tabs by welding. After the connection is completed, check the connection quality of the flexible circuit board, including the continuity of the circuit, whether there is a short circuit, whether the installation position of the flexible circuit board in the battery module body 11 is correct, and whether it will be squeezed or rubbed.

[0052] S5: Thermal management of the battery module body 11. A heat dissipation device is installed to manage the thermal performance of the battery module body 11, thereby completing the assembly of the battery module body 11. The specific steps include the following:

[0053] S501: Design the layout of the water cooling pipes, fit the water cooling pipes tightly against the heat-generating parts of the battery module body 11, install a water pump in the water cooling pipes to drive the coolant circulation, and configure a heat exchanger, temperature sensor and control system to adjust the water pump flow and the working status of the heat exchanger according to the temperature of the battery module.

[0054] S502: The phase change material is encapsulated in a container, and then the container is installed inside the battery module body 11. During the installation process, it is necessary to ensure that the phase change material and the battery module have good thermal contact.

[0055] By screening and matching battery cells, it can be ensured that the battery module can work stably and efficiently in actual use. This can avoid poor contact, power loss, and inconsistent charging and discharging during the operation of the battery module body 11. It can also ensure that the power loss of each battery cell is relatively consistent during long-term storage and use. With the set assembly fixture body 1, the internal space of the battery module body 11 can be adjusted according to the usage requirements during assembly. This allows it to be adapted to the assembly of battery module bodies 11 of various sizes, as well as long and heavy battery module bodies 11, thus ensuring the assembly range of the assembly fixture body 1.

[0056] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method of assembling a long dimension high weight battery module, characterized by: The method comprises the following steps: S1: prepare the assembly fixture body (1), the two ends of the top of the assembly fixture body (1) are symmetrically provided with bearing seats (3), the opposite sides of the two bearing seats (3) are provided with bidirectional screw rods (4), the outer wall of the assembly fixture body (1) is provided with a servo motor (5), the servo motor (5) is connected with the bidirectional screw rod (4) through a driving shaft, and the bottom of the assembly fixture body (1) is provided with a supporting column (2); The two ends of the top of the assembly fixture body (1) are symmetrically movably connected with clamping plates (8), the bottoms of the opposite sides of the two clamping plates (8) are symmetrically provided with assembly seats (7), and the bottom of the assembly seat (7) is screw-connected to the outer wall of the bidirectional screw rod (4) in the middle; The top of the assembly fixture body (1) is provided with guide rails (6), the bottom of the assembly seat (7) is movably connected to the outer wall of the guide rail (6), a linear motor (9) is arranged in the inner cavity of one end of the clamping plate (8), and the driving end of the linear motor (9) is provided with a connecting frame (10); S2: battery cell screening and pairing, high-precision testing equipment is used to screen and pair the battery cells, so as to ensure the consistency of the performance and capacity of the battery cells; S3: battery cell stacking and fixing, the screened and paired battery cells are stacked together according to the design requirements, and the battery cells are fixed in the module frame through the assembly fixture body (1), so as to form a battery module body (11); S4: electrical connection of the battery module body (11), the connecting parts of the battery cells are prepared, the welding surfaces of the battery cell connecting parts are cleaned and pretreated, oil stains and oxides are removed, the battery cells are placed according to the design requirements, the parameters of the laser welding equipment are adjusted, the laser beam is accurately irradiated on the connecting parts for welding, after the welding is completed, the welding quality is checked, including appearance inspection and electrical performance test; S5: thermal management of the battery module body (11), a heat dissipation device is installed to perform thermal management on the battery module body (11), so as to complete the assembly work of the battery module body (11).

2. The method of claim 1, wherein: The guide rail (6) has four groups, and the bottoms of the two sides of the two assembly seats (7) are movably connected to the outer walls of the four groups of guide rails (6).

3. The method of claim 1, wherein: In the S2, the battery cell screening and pairing specifically comprises the following steps: S201: capacity test, the charging and discharging current and voltage are accurately controlled by using a high-precision battery charging and discharging tester, and relevant data are recorded, and a plurality of battery cells are tested, and the battery cells with a capacity difference within ±2% are paired together; S202: internal resistance test, a battery internal resistance tester is used, and the battery cells with an internal resistance difference within ±10% are paired together; S203: open circuit voltage test, a high-precision voltmeter is used to measure the open circuit voltage of the battery, and the battery cells with an open circuit voltage difference within ±50 mV are paired together; S204: self-discharge rate test, a thermostat is used to control the test environment temperature, a high-precision voltmeter is used to measure the voltage, and the battery cells with a self-discharge rate difference within ±0.1% are selected for pairing. S205: Dynamic performance test, using a battery test system that can simulate different charge and discharge rates, and temperature sensors to monitor the temperature changes of the battery cells during charging and discharging, according to the results of the dynamic performance test, the battery cells with similar performance under simulated actual working conditions are paired together.

4. The method of claim 1, wherein: In the S3, the battery cell stacking and fixing specifically includes the following operation steps: S301: Prepare the frame, place it on the top of the assembly fixture body (1), connect it to one end of the connecting frame (10), start the servo motor (5), drive the bidirectional screw rod (4) to rotate, so that the bottom of the assembly seat (7) can be screwed with the bidirectional screw rod (4), at this time the clamping plates (8) at both ends can be moved to the opposite side, so that the frame can be clamped; S302: Start the linear motor (9), move the frame through the connecting frame (10), the battery cells that have been screened and paired can be stacked together according to the design requirements, and then installed in the inner cavity of the frame to form the battery module body (11).

5. The method of claim 1, wherein: In the S4, it also includes the connection of conductive glue and flexible circuit board, wherein the connection of conductive glue: select conductive glue, match it according to the material and working environment of the battery connection component, evenly coat the conductive glue on the connection part, then adhere the battery cells and connection components together according to the design requirements, and solidify according to the solidification requirements of the conductive glue, after solidification, check the firmness and electrical performance of the connection; The connection of flexible circuit board: design the layout of the flexible circuit board to meet the electrical connection requirements of the battery module body (11), connect the flexible circuit board and the battery tab by welding, after connection, check the connection quality of the flexible circuit board, including the continuity of the circuit, whether there is short circuit, whether the installation position of the flexible circuit board in the battery module body (11) is correct, whether it will be squeezed or rubbed.

6. The method of claim 1, wherein: In the S5, the heat management of the battery module body (11) specifically includes the following operation steps: S501: Design the layout of the water cooling pipe, tightly adhere the water cooling pipe to the heating part of the battery module body (11), install the water pump in the water cooling pipe to drive the circulation of the cooling liquid, and configure the heat exchanger, temperature sensor and control system, adjust the flow of the water pump and the working state of the heat exchanger according to the temperature of the battery module; S502: Encapsulate the phase change material in the container, then install the container in the inside of the battery module body (11), during installation, ensure good thermal contact between the phase change material and the battery module.

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