Self-positioning function for assembly

Abstract

A sheet metal component assembly includes a first component having at least one positioning opening formed therein, and a second component mounted to the first component. The second component includes a second component body and at least one positioning boss formed in and extending from the second component body. At least one positioning boss is mounted in the at least one positioning opening to position the second component at the first component. A rechargeable energy storage system (RESS) includes a tray, one or more RESS units located on the tray, and a cover mounted to the tray to close the RESS. The cover comprises a cover body and at least one positioning boss, and the at least one positioning boss is formed in the cover body and extends from the cover body. At least one positioning boss is mounted in at least one positioning opening in the tray to position the cover at the tray.

Description

Technical Field

[0001] This disclosure relates to components for two parts of a vehicle, such as vehicle components, such as a rechargeable energy storage system (RESS) or a battery system. Background Technology

[0002] A typical RESS assembly includes a cap attached to it. The assembly process of this cap onto the RESS assembly relies on manual operation to correctly position the cap onto the RESS assembly, specifically the RESS tray. This manual process is incompatible with highly automated assembly facilities. The goal is to make the RESS cap installation process feasible and compatible with automated assembly processes without introducing significant changes to design and manufacturing processes. Summary of the Invention

[0003] In one exemplary embodiment, the metal plate component assembly includes a first component and a second component. The first component has at least one positioning opening formed therein, and the second component is mounted to the first component. The second component includes a second component body and at least one positioning boss formed in and extending from the second component body. The at least one positioning boss is mounted into the at least one positioning opening to position the second component at the first component.

[0004] In addition to one or more features described herein, the at least one positioning boss is one of a continuous cylindrical or conical element extending from the second component body.

[0005] In addition to one or more features described herein, the at least one positioning boss includes two or more discontinuous boss legs extending from the second component body.

[0006] In addition to one or more features described herein, at least one leg bridging portion is spaced apart from the second component body and connects two adjacent boss legs of two or more boss legs.

[0007] In addition to one or more features described herein, the at least one leg bridging portion is substantially linear, W-shaped, or U-shaped.

[0008] In addition to one or more features described herein, at least one locating pin is mounted in at least one locating boss and extends into at least one locating opening.

[0009] In addition to one or more features described herein, the at least one positioning boss is formed by one or more of die cutting, stamping, laser cutting, waterjet cutting, hole extrusion, or flanging.

[0010] In another exemplary embodiment, the rechargeable energy storage system (RESS) includes a tray, one or more RESS batteries located on the tray, and a cover mounted to the tray to close the RESS. The cover includes a cover body and at least one positioning boss formed in and extending from the cover body. The at least one positioning boss is fitted into at least one positioning opening in the tray to position the cover at the tray.

[0011] In addition to one or more features described herein, the at least one positioning boss is one of a continuous cylindrical or conical element extending from the cover.

[0012] In addition to one or more features described herein, the at least one positioning boss includes two or more discontinuous boss legs extending from the cover.

[0013] In addition to one or more features described herein, at least one leg bridging portion is spaced apart from the cover body and connects two adjacent boss legs of two or more boss legs.

[0014] In addition to one or more features described herein, the at least one leg bridging portion is substantially linear, W-shaped, or U-shaped.

[0015] In addition to one or more features described herein, at least one locating pin is mounted in at least one locating boss and extends into at least one locating opening.

[0016] In addition to one or more features described herein, the at least one positioning boss is formed by one or more of die cutting, stamping, laser cutting, waterjet cutting, hole extrusion, or flanging.

[0017] In yet another exemplary embodiment, a vehicle includes a body, a propulsion system for driving the vehicle, and a rechargeable energy storage system (RESS) operably connected to the propulsion system to power the propulsion system. The RESS includes a tray, one or more RESS units located on the tray, and a cover mounted to the tray to close the RESS. The cover includes a cover body and at least one positioning boss formed in and extending from the cover body. The at least one positioning boss is mounted into at least one positioning opening in the tray to position the cover at the tray.

[0018] In addition to one or more features described herein, the at least one positioning boss is one of a continuous cylindrical or conical element extending from the cover.

[0019] In addition to one or more features described herein, the at least one positioning boss includes two or more discontinuous boss legs extending from the cover.

[0020] In addition to one or more features described herein, at least one leg bridging portion is spaced apart from the cover body and connects two adjacent boss legs of two or more boss legs.

[0021] In addition to one or more features described herein, the at least one leg bridging portion is substantially linear, W-shaped, or U-shaped.

[0022] In addition to one or more features described herein, at least one locating pin is mounted in at least one locating boss and extends into at least one locating opening.

[0023] The above-described features and advantages, as well as other features and advantages of this disclosure, will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0024] Other features, advantages, and details appear by way of example only in the following detailed description, which refers to the accompanying drawings, wherein:

[0025] Figure 1 This is a schematic diagram of an exemplary embodiment of the vehicle;

[0026] Figure 2 This is a schematic cross-sectional view of an embodiment of the vehicle's RESS;

[0027] Figure 3 This is a schematic cross-sectional view of an embodiment of the pallet positioning feature;

[0028] Figure 4 This is a schematic cross-sectional view of another embodiment of the pallet positioning feature;

[0029] Figure 5 It is a plan view of the cut pattern of the implementation scheme of the discontinuous pallet positioning feature;

[0030] Figure 6 yes Figure 5 Perspective view of an embodiment;

[0031] Figure 7 This is a plan view of the cutout pattern of another embodiment of the discontinuous pallet positioning feature;

[0032] Figure 8 yes Figure 7 Perspective view of an embodiment;

[0033] Figure 9 It is a plan view of the cutout pattern of an embodiment including the discontinuous pallet positioning features of the support leg bridging section;

[0034] Figure 10 yes Figure 9Perspective view of an embodiment;

[0035] Figure 11 It is a plan view of the cutout pattern of another embodiment of the discontinuous pallet positioning feature including the leg bridging section;

[0036] Figure 12 It is a plan view of the cutout pattern of another embodiment of the discontinuous pallet positioning feature including the leg bridging section;

[0037] Figure 13 yes Figure 12 Perspective view of an embodiment;

[0038] Figure 14 It is a plan view of a cutout pattern of another embodiment of the discontinuous pallet positioning feature including the leg bridging portion;

[0039] Figure 15 yes Figure 14 Perspective view of an embodiment;

[0040] Figure 16 It is a plan view of a cutout pattern of another embodiment of the discontinuous pallet positioning feature including the leg bridging portion;

[0041] Figure 17 yes Figure 16 Perspective view of an embodiment;

[0042] Figure 18 It is a plan view of the cutout pattern of another embodiment of the discontinuous pallet positioning feature including the leg bridging section;

[0043] Figure 19 yes Figure 18 Perspective view of an embodiment; and

[0044] Figure 20 This is a partial cross-sectional view of an embodiment including the locating pin. Detailed Implementation

[0045] The following description is exemplary in nature only and is not intended to limit this disclosure, its application, or use. It should be understood that throughout the drawings, corresponding reference numerals denote the same or corresponding parts and features.

[0046] According to an exemplary embodiment, the vehicle according to the non-limiting example is in Figure 1The vehicle 10 is generally indicated by the number 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. In a non-limiting example, two of the wheels 16 are steerable. The body 12 partially defines a passenger compartment 20 having seats 22 positioned behind an instrument panel 26. A steering controller 30 is disposed between the seats 22 and the instrument panel 26. The steering controller 30 is operated to control the orientation of one or more steerable wheels. The vehicle 10 includes an electric motor 34 connected to a transmission, which powers one or more of the wheels 16. A rechargeable energy storage system (RESS) assembly 38 supplies power to the electric motor 34.

[0047] Now for reference Figure 2 The diagram shows a cross-sectional view of an exemplary embodiment of the RESS assembly 38. The RESS assembly 38 includes a tray 42 in which a plurality of cells 44 are disposed. To close the RESS assembly 38, a cover 46 is mounted thereon. The tray 42 includes a tray flange 48, which in some embodiments defines an outer periphery of the tray 42. Similarly, the cover 46 includes a cover flange 50, which in some embodiments defines an outer periphery of the cover 46. To secure the cover 46 to the tray 42, a plurality of fasteners 52 are mounted through the cover flange 50 and the tray flange 48. In some embodiments, the cover 46 and / or the tray 42 are formed of a sheet metal material. However, those skilled in the art will readily understand that the cover 46 and / or the tray 42 may be formed of another material, such as plastic or fiber-reinforced composite material.

[0048] Although the following description is directed to RESS component 38, those skilled in the art will readily understand that this disclosure can be readily applied to other components of both parts. During the assembly process, it is desirable to accurately and easily position the cover 46 onto the tray 42 before installing the multiple fasteners 52. Referring now... Figure 3 The cover 46 includes one or more locating bosses 54 formed in the cover flange 50. These locating bosses 54 insert into corresponding locating openings 56 in the tray flange 48. While this arrangement has been shown and described herein, those skilled in the art will readily understand that in some embodiments, the configuration may be substantially reversed, wherein the locating bosses 54 are formed in the tray flange 48 and inserted into corresponding locating openings 56 in the cover flange 50 to position the cover 46 relative to the tray 42 during assembly. Figure 3 In one embodiment, the positioning boss 54 is continuous around the boss opening 58 in the cover flange 50 and extends perpendicularly to the cover flange 50 into the positioning opening 56 in the tray flange 48. In this configuration, the boss opening 58 is formed in the cover flange 50, and the positioning boss 54 is formed by, for example, an extrusion process. In another embodiment, for example... Figure 4As shown, the positioning boss 54 can be formed into another shape by extrusion. For example, in Figure 4 In some embodiments, the positioning boss 54 has a truncated conical shape. In some embodiments, such as Figure 3 As best shown, the positioning boss 54 has a boss height 60 that achieves a minimum height greater than the thickness of the adhesive layer 62 between the tray flange 48 and the cover flange 50, to ensure that the positioning boss 54 is at least partially inserted into the positioning opening 56. In some embodiments, the minimum boss height 60 is greater than or equal to 7 mm.

[0049] In other embodiments, the positioning boss 54 is discontinuous around the boss opening 58, such as... Figure 5-8 As shown. The positioning boss 54 has one or more boss legs 64 positioned around the boss opening 58. In some embodiments, such as in Figure 5 and Figure 6 In the middle, the positioning boss 54 includes two boss legs 64. The boss opening 58 is cut to form a cut pattern, such as... Figure 5 As shown, when formed after cutting, the boss leg 64 extends outward from the cover flange 50, such as... Figure 6 As shown. See again. Figure 5 The configuration of the positioning boss 54 can be varied by the number and symmetry of the boss legs 64, the size of the boss opening 58, the leg length 66, the leg fillet radius 68, and other parameters such as the leg base width 70 and the leg end width 72. Those skilled in the art will readily understand that the listed parameters are merely exemplary and other parameters can be used depending on the configuration of the positioning boss 54. In another embodiment, as... Figure 7 and Figure 8 As shown, changing these parameters results in the boss leg 64 having a length that is essentially triangular, with the leg end width 72 being zero or close to zero. See again... Figure 5 In some embodiments, the stress-relief cut can be incorporated into the rounded corner region 74 of the positioning boss 54 to reduce the risk of breakage. Additionally, during forming after cutting, if the material's formability allows, a degree of stretching of the material can be performed to increase the overall stiffness of the positioning boss 54.

[0050] In other embodiments, such as Figure 9 and Figure 10 As shown, the positioning boss 54 includes a plurality of boss legs 64, wherein adjacent boss legs 64 are interconnected at or near the leg ends 76 by leg bridging portions 78 extending between two adjacent boss legs 64. The leg bridging portions 78 increase the overall structural integrity and rigidity of the positioning boss 54 while still allowing the cover 46 to be precisely positioned onto the tray 42. The leg bridging portions 78 are configured to have sufficient length when formed in a flat state, such as... Figure 9 As shown, to allow in the formation of Figure 10 The positioning boss 54 shown is constructed to be straightened and reshaped without introducing tension. Furthermore, it is desirable to avoid stress concentration in the leg bridging section 78 by utilizing a relatively large fillet radius.

[0051] Now for reference Figure 11 The positioning boss 54, including the leg bridging portion 78, is constructed by changing key parameters (e.g., bridging length 80). The bridging length 80 must be long enough to prevent breakage of the leg bridging portion during the formation of the positioning boss. The outer opening angle 82 of the bridging portion must be large enough to achieve the required bridging length 80, but not too large to reduce the rigidity of the structure. The leg bridging portion 78 includes an inner opening angle 84 defined between the leg bridging portion 78 and the adjacent boss leg 64. This inner opening angle 84 is designed to be large enough to accommodate the leg bridging portion from the adjacent boss leg 64. Figure 11 The flat structure is reshaped into Figure 10 The extension construction reduces stress concentration between the leg bridging portion 78 and the boss leg 64. However, if the inner opening angle 84 is too large, it undesirably reduces the size of the boss leg 64. The inner bridging radius 86 is designed to reduce strain concentration when formed into an extension construction. The outer bridging distance 88 from the boss axis 90 determines the position of the leg bridging portion 78 along the boss leg 64, while the inner bridging distance 92, together with the outer bridging distance 88, determines the bridging width of the leg bridging portion 78.

[0052] An exemplary embodiment including the positioning boss 54 of the outrigger bridge portion 78 is in Figure 12-19 As shown in [the image]. Figure 12 and Figure 13 In the embodiments, each of the leg bridging portions 78 is formed as follows: Figure 12 The parabolic shape shown is formed when the positioning boss 54 is shaped as follows: Figure 13 In the extended position shown, this results in the leg bridging portion 78 having a substantially linear configuration extending between adjacent boss legs 64. Figure 14 and Figure 15 In one embodiment, the leg bridging portion 78 is formed in the shape of a clover, such as... Figure 15 As shown, when the positioning boss 54 is formed to the extended position, this results in the leg bridge portion 78 having a W shape. Figure 16-19 In one embodiment, the leg bridging portion 78 is formed in a U-shape, such as... Figure 16 and 18 As shown. When the positioning bosses 54 are respectively formed to the shape shown. Figure 17 and 19 In the extended position shown, the leg bridging portion 78 has a flat U-shape.

[0053] Although in some embodiments, the locating boss 54 is used alone to position the cover 46 to the tray 42, in cases such as Figure 20 In other embodiments shown, the locating pin 94 is mounted in the boss opening 58 and supported by the legs 64 of the locating boss 54. The locating pin 94 is then used in conjunction with the locating boss 54 to position the cover 46 onto the tray 42.

[0054] To form the positioning boss 54, a cut pattern defining the boss legs 56 and leg bridging portions 78 (if included) is formed in a flat state using methods such as die cutting, stamping, laser cutting, or waterjet cutting. After forming the cut pattern, the positioning boss 54 is then formed to its extended position. This can be achieved, for example, by taper or flat punch and die operation. Tolerances between the punch and die are selected and maintained to achieve a selected amount of material ironing during the forming operation. Tooling insertion or partial modifications to the punch and / or die can be performed without completely altering the forming tooling, thus saving tooling costs.

[0055] The term “a” does not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0056] When an element, such as a layer, film, region, or substrate, is referred to as being “on” another element, it can be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being “directly” on another element, there are no intermediate elements present.

[0057] Unless otherwise stated herein, all test standards are the most recent standards in effect as of the date of filing of this application, or, if priority is claimed, the date of filing of the earliest priority application in which a test standard appears.

[0058] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0059] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A metal plate component assembly, comprising: The first component has at least one positioning opening formed therein; as well as A second component is installed onto the first component, the second component comprising: Second component body; as well as At least one positioning boss is formed in and extends from the second component body, and the at least one positioning boss is mounted into the at least one positioning opening to position the second component at the first component.

2. The metal plate component assembly according to claim 1, wherein, The at least one positioning boss is one of a continuous cylindrical or conical element extending from the body of the second component.

3. The metal plate component assembly according to claim 1, wherein, The at least one positioning boss includes two or more discontinuous boss legs extending from the body of the second component.

4. The metal plate component assembly according to claim 3, further comprising at least one leg bridging portion, the at least one leg bridging portion being spaced apart from the second component body and connecting two adjacent boss legs of the two or more discontinuous boss legs.

5. The metal plate component assembly of claim 1, further comprising at least one locating pin, the at least one locating pin being mounted in the at least one locating boss and extending into the at least one locating opening.

6. A rechargeable energy storage system, namely RESS, comprising: tray; One or more RESS units are located on a tray; as well as A cover, the cover being mounted to the tray to close the RESS, the cover comprising: Cover; as well as At least one positioning boss is formed in and extends from the cover body, and the at least one positioning boss is mounted into at least one positioning opening in the tray to position the cover at the tray.

7. The RESS according to claim 6, wherein, The at least one positioning boss is one of a continuous cylindrical or conical element extending from the cover.

8. The RESS according to claim 6, wherein, The at least one positioning boss includes two or more discontinuous boss legs extending from the cover.

9. The RESS of claim 8 further includes at least one leg bridging portion, the at least one leg bridging portion being spaced apart from the cover and connecting two adjacent boss legs of the two or more discontinuous boss legs.

10. A vehicle comprising: Body; A propulsion system for driving the movement of the vehicle; as well as The rechargeable energy storage system according to any one of claims 6-9, wherein the rechargeable energy storage system is operatively connected to the propulsion system to provide power to the propulsion system.

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