Battery module positioning tool, battery package assembly system and assembly method

Abstract

The application discloses a battery module positioning tool, a battery package assembling system and an assembling method. The battery module positioning tool comprises a first tray and a second tray. The second tray comprises a fixed support frame and at least two groups of sliding support frames which are arranged at intervals along a Y direction and slide on the fixed support frame. The sliding support frame comprises at least two groups of rectangular frames to form a battery module accommodating space. A plurality of blocking blocks arranged in a matrix and extending along a Z direction are arranged on the first tray, and the blocking blocks are used for limiting the installation position of the battery module along an X direction. A Y direction adjusting assembly comprises a first linear execution assembly arranged outside the battery module accommodating space and an adjusting plate between adjacent battery module accommodating spaces along the Y direction. The output end of the first linear execution assembly can act on the battery module through the adjusting plate to adjust the Y direction installation position of the battery module. The application can improve the positioning accuracy of the battery module and avoid the alignment difficulty caused by multi-direction coupling in the traditional tool.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle battery installation, and in particular to a battery module positioning fixture, a battery pack assembly system, and an assembly method. Background Technology

[0002] During the rapid development of the electric vehicle industry, traditional battery pack structures (CTM) suffer from significant drawbacks, including severe space waste, redundant costs and weight, and low production efficiency, making it difficult to meet the industry's core demands for increased range, cost control, and platform-based development. Against this backdrop, the CTP (Continuous To-Pack) battery pack structure has emerged. This structure eliminates the module layer, achieving direct integration from the cell to the battery pack, significantly reducing the space occupied and cost of structural components. It effectively breaks through the physical space and cost limitations of traditional battery packs, becoming the mainstream direction for current battery pack development.

[0003] Laser welding of battery terminals is a core process in CTP battery pack assembly. Its welding pass rate directly determines the electrical performance and safety of the battery pack, and the consistency of cell terminal height is a crucial prerequisite for ensuring welding quality. In practice, by stacking cells upside down and using the terminal surface as a positioning reference, the consistency of cell terminal height can be maximized. The battery casing inverted insertion process perfectly adapts to this inverted stacking method, becoming a key step in CTP battery pack assembly.

[0004] However, the existing inverted packing process has significant technical bottlenecks: on the one hand, it is difficult to achieve precise positioning and reliable limiting of the product in the X / Y / Z directions; on the other hand, during the pressing process, the product is prone to displacement due to the expansion force of the foam when it detaches from the tooling, leading to a decrease in positioning accuracy. This, in turn, can cause connection failures during battery expansion and vibration, seriously affecting the assembly quality and safety of the battery pack. Furthermore, existing assembly tooling lacks versatility and cannot adapt to different battery module configurations, and the tray structure design is unreasonable, making it difficult to ensure that the X / Y / Z position is always controlled in each process. Summary of the Invention

[0005] Therefore, this invention proposes a battery pack inverted box assembly fixture and method that can reliably position the battery pack into the battery box.

[0006] To address the aforementioned technical problems, the present invention provides the following technical solution: A battery module positioning fixture includes: a first tray located on the lower side and a second tray located on the upper side of the first tray. The second tray includes a fixed support frame and at least two sets of sliding support frames spaced apart along the Y direction and sliding on the fixed support frame. The sliding support frames include at least two sets of rectangular frames to form a battery module accommodating space. The first tray is provided with a plurality of blocking blocks arranged in a matrix and extending along the Z direction. The blocking blocks are used to limit the installation position of the battery module along the X direction. A Y-direction adjustment component includes a first linear actuator disposed outside the battery module accommodating space and an adjustment plate located between adjacent battery module accommodating spaces along the Y direction. The output end of the first linear actuator can act on the battery module through the adjustment plate to adjust the Y-direction installation position of the battery module.

[0007] In some embodiments of the present invention, the fixed support frame is provided with a slide rail extending along the Y direction, and a plurality of rectangular frames arranged along the X direction are slidably connected to the slide rail of the fixed support frame through a set of sliding support blocks, and the two ends of the adjusting plate are fixedly connected to the sliding support blocks through lugs.

[0008] In some embodiments of the present invention, an elastic reset assembly 26 is further provided between two adjacent sets of sliding support blocks along the Y direction. The assembly includes a push rod disposed on one set of the sliding support blocks and extending along the Y direction, a slider disposed on the other set of the sliding support blocks and slidable along the Y direction, a stop block spaced apart from the slider, and an elastic member located between the stop block and the slider; wherein the end of the push rod extends to the end near the slider.

[0009] In some embodiments of the present invention, the first linear actuator includes a lead screw and nut transmission assembly and a drive plate extending along the X direction. The drive plate is connected to the output end of the lead screw and nut transmission assembly that moves linearly, and the extension length of the drive plate covers the length of the battery module accommodating space along the X direction.

[0010] In some embodiments of the present invention, the first linear actuator is in two sets, which are respectively installed on both sides of the fixed support frame along the Y direction. The two sets of the first linear actuator act synchronously on the two battery modules located on the outermost side of the Y direction.

[0011] In some embodiments of the present invention, a second linear actuator is provided on the first tray, and the blocking block can slide along the X direction under the action of the second actuator.

[0012] The present invention also provides a battery pack assembly system, including the battery module positioning fixture described in any of the above embodiments, and further including a flipping fixture. The flipping fixture includes a flipping mounting base for accommodating the component C to be flipped and a lifting mechanism for controlling the flipping mounting base to slide along the Z direction; wherein, the flipping mounting base is provided with a flipping drive component for driving the component C to be flipped to rotate around a horizontal axis.

[0013] In some embodiments of the present invention, the second tray is provided with a connecting block, and the flip mounting base is provided with a support base connected to the connecting block and a third linear actuator for controlling the support base to move along the Z direction.

[0014] This invention also provides a battery pack assembly method, comprising the following steps: Multiple battery modules are placed in the battery module accommodating space of the second tray. Two adjacent sets of the barrier blocks along the X direction restrict the X-direction position of one set of battery modules. The Y-direction adjustment component is adjusted so that the battery modules are stacked along the Y direction to the set position. The battery pack housing B is inverted and placed on the upper side of the battery accommodating space, so that the stacked battery module is partially accommodated inside the battery pack housing B, forming the component C to be flipped. Move the component C to be flipped to the work station where the flipping fixture is located, control the lifting mechanism to lower the flipping mounting base to the area of ​​the component C to be flipped, connect the flipping mounting base to the second tray, and control the second linear actuator to move the second tray upward until the second tray is completely separated from the first tray. Remove the first tray and connect the second tray to the battery pack housing B. The lifting mechanism is controlled to raise the flipping mounting base to a set position, and then the rotation drive component is controlled to rotate the flipping mounting base 180° around the horizontal axis, so as to flip the component C to be flipped. After the lifting mechanism is controlled to lower the flip mounting base to the set position, the connection between the second tray and the battery pack housing B is released.

[0015] In some embodiments of the present invention, two sets of the first linear actuators are arranged along the Y direction, and the first linear actuators are controlled to operate synchronously, so that the battery modules located on both sides are stacked towards the middle region.

[0016] The technical solution of the present invention has the following technical effects compared with the prior art: In the battery module positioning fixture provided by this invention, X-axis positioning is achieved by a matrix of blocking blocks on the first tray, and Y-axis positioning is achieved by a sliding support frame in conjunction with a first linear actuator. The adjustment mechanisms are independent of each other and do not interfere with each other, avoiding the alignment difficulties caused by multi-directional coupling in traditional fixtures. This positioning fixture achieves high positioning accuracy for the battery module.

[0017] Furthermore, the elastic reset component 26 in this positioning fixture transforms rigid pushing into flexible pushing, avoiding impact and squeezing between adjacent modules. By selecting the stiffness of the elastic element, the preload between modules can be precisely set, ensuring both stacking tightness and preventing cell deformation under pressure. Simultaneously, the dual-sided centering drive reduces unilateral cumulative error, improves stacking symmetry, and ensures that the center of the module array highly coincides with the center of the fixture. Attached Figure Description

[0018] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, which will help to understand the purpose and advantages of the present invention, wherein: Figure 1 This is a schematic diagram of a specific embodiment of the battery module positioning fixture of the present invention; Figure 2 Another structural schematic diagram of a specific embodiment of the battery module positioning fixture of the present invention; Figure 3 This is a schematic diagram showing the fit between the battery module and the rectangular frame provided by this invention. Figure 4 This is a schematic diagram of the structure of the first tray in the battery module positioning fixture of the present invention; Figure 5 This is a top view of a portion of a specific embodiment of the battery module positioning fixture of the present invention. Figure 6 This is a top view of the elastic reset component of the battery module positioning fixture of the present invention; Figure 7 This is a schematic diagram of the structure of the first linear actuator in the battery module positioning fixture of the present invention; Figure 8 This is a schematic diagram of the structure of the component to be flipped according to the present invention; Figure 9 This is a schematic diagram illustrating the cooperation relationship between the flipping fixture and the component to be flipped according to the present invention; Figure 10 This is a schematic diagram showing the connection relationship between the flipping fixture and the second tray of the present invention. Detailed Implementation

[0019] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] In the following text, "X-direction," "Y-direction," and "Z-direction" refer to three mutually orthogonal directions. The X-direction is the length direction of the battery module (i.e., the arrangement direction of the cells within a single module), the Y-direction is the stacking direction of the battery modules within the battery pack (i.e., the direction in which multiple modules are arranged side-by-side), and the Z-direction is the height direction of the battery module (i.e., the direction from the bottom of the module to the top cover). This definition is for descriptive convenience only and does not constitute a limitation on the actual installation direction.

[0023] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0024] Figure 1 , Figure 2 The illustration shows a specific embodiment of the battery module positioning fixture provided by the present invention, which is used for high-precision spatial positioning of multiple battery modules during the assembly of lithium-ion battery packs, solid-state battery packs, or other types of power battery packs. The fixture includes a first tray 10 and a second tray 20 located above the first tray 10. The first tray 10 and the second tray 20 are stacked vertically in the initial assembly state, maintaining a small gap or direct contact between them when no external force is applied, but without a fixed connection, thus allowing subsequent relative movement in the Z-axis. The first tray 10 is typically fixedly mounted on a work platform or base, forming the absolute reference for the entire fixture. The second tray 20, as a movable component carrying the battery modules, can translate relative to the first tray 10 under the action of a Y-axis adjustment component.

[0025] The second tray 20 generally includes a fixed support frame 21 and at least two sets of sliding support frames 22 that are spaced apart along the Y direction and slidably connected to the fixed support frame 21. The fixed support frame 21 is the skeleton of the second tray 20 and is usually made of high-strength aluminum alloy profiles or welded steel plates, possessing sufficient rigidity and flatness. The fixed support frame 21 is provided with guide structures extending along the Y direction. The number of sliding support frames 22 is determined according to the number of battery modules arranged side by side along the Y direction in the battery pack. For example, for a standard battery pack, two, three, or four sets of sliding support frames 22 can be provided.

[0026] Each set of sliding support frames 22 consists of at least two sets of rectangular frames 221, which are arranged along the X-direction and fixedly connected to each other (e.g., by welding or bolting beams). Unlike conventional closed rectangular frame frames 221, the rectangular frames 221 in this design adopt a layered beam structure. Specifically, as... Figure 3 , Figure 5 As shown, each rectangular frame 221 is formed by connecting a first beam 2211 and a second beam 2212, and a third beam 2213 and a fourth beam 2214, which are arranged relatively parallel to each other. The first beam 2211 and the second beam 2212 are located above the third beam 2213 and the fourth beam 2214. The first beam 2211 and the second beam 2212 extend along the X-direction and are parallel to each other. Their upper surfaces are machined into planes to directly support the two terminals of the battery module; that is, the positive and negative terminals of the battery module are located above the first beam 2211 and the second beam 2212, respectively. The third beam 2213 and the fourth beam 2214 are located below, extending downwards along the Z-direction to a certain height. When the sliding support frame 22 slides along the Y-direction on the fixed support frame 21, the corresponding rectangular frame 221 and the battery module inside it move accordingly, realizing the adjustment of the Y-direction position. By placing the electrode post directly on the upper surfaces of the first beam 2211 and the second beam 2212, the rectangular frame 221 not only serves as a limit in the X and Y directions but also acts as a support surface for the module in the Z direction. Since the electrode post is a part of the battery module with high structural strength and strict positional accuracy requirements, using it as a positioning reference can effectively avoid positioning errors caused by manufacturing tolerances of the module housing.

[0027] like Figure 2 , Figure 4As shown, the upper surface of the first tray 10 is provided with a plurality of barrier blocks 11 arranged in a matrix and extending vertically along the Z direction. These barrier blocks 11 can be made of rigid nylon, polyurethane, or metal blocks with a rubber-coated surface to avoid rigid collision with the battery module casing. The barrier blocks 11 are arranged on the first tray 10 in a grid-like layout with multiple columns along the X direction and multiple rows along the Y direction. The spacing between two adjacent columns of barrier blocks 11 corresponds to the X-direction length of the battery module. When the battery module is placed into the space defined by the rectangular frame 221 and the barrier blocks 11 by the clamping mechanism, the barrier blocks 11 directly abut against the side of the battery module, thereby restricting the installation position of the battery module along the X direction. Since the barrier blocks 11 are independent components fixed to the first tray 10, and the first tray 10 itself can generate relative movement in the Z direction with the second tray 20, the battery module will detach from the barrier blocks 11 when the second tray 20 rises under the action of the Z-direction adjustment component.

[0028] like Figure 2 , Figure 5 As shown, the Y-axis adjustment assembly includes a first linear actuator 24 disposed outside the battery module accommodating space, and an adjustment plate 23 located between adjacent battery module accommodating spaces along the Y-axis. "Outer side" refers to the outer ends of the battery module array arranged integrally along the Y-axis. The output end of the first linear actuator 24 extends and retracts along the Y-axis. The adjustment plate 23 is a plate with sufficient rigidity, extending in the X-axis direction in its length direction and in the Z-axis direction in its width direction. The adjustment plate 23 is disposed between two adjacent sets of sliding support frames 22, and maintains contact with or is fixed to the sliding support frames 22 on both sides via connectors. When the first linear actuator 24 is activated, its output end pushes the outermost adjustment plate 23, which transmits force to the adjacent sliding support frame 22, thereby causing the sliding support frame 22 and the battery modules inside it to move along the Y-axis. During movement, the sliding support frame 22 pushes the innermost sliding support frame 22 via the adjusting plate 23 on the other side, and so on, until all battery modules are stacked along the Y direction to a set reference position (e.g., aligned on one side or symmetrically centered). The structure of the Y-direction adjustment assembly allows for the adjustment of the Y-direction position of multiple modules with only one active actuator, avoiding the cost and control complexity of setting up a separate drive device for each module. At the same time, because the contact surface between the adjusting plate 23 and the sliding support frame 22 is large, the thrust can be evenly distributed on the sliding support frame 22, preventing off-center loading and jamming caused by single-point force.

[0029] In addition, when there is a manufacturing tolerance in the Y-direction dimension of the battery module, the continuous pressure applied by the first linear actuator 24 can make all modules stack tightly along the Y-direction, thereby transferring the dimensional tolerance of each module to the outermost gap without affecting the tightness of the bonding between the modules.

[0030] Specifically, in one alternative implementation, such as Figure 2 As shown, a slide rail extending along the Y direction is fixedly installed on the fixed support frame 21. The slide rail can be an industrial standard linear guide to ensure motion stability. Several rectangular frames 221 arranged along the X direction are slidably connected to the slide rail of the fixed support frame 21 through a set of sliding support blocks 25. Specifically, for a set of sliding support frames 22 (i.e., all rectangular frames 221 arranged in a row along the X direction), they are all fixedly installed on a single sliding support block 25. The sliding support block 25 is a long strip-shaped plate or block-shaped component, and its lower surface is provided with a slider or groove that mates with the slide rail. The length direction of the sliding support block 25 extends along the X direction, covering the installation positions of all rectangular frames 221 in the row. The third beam 2213 or the fourth beam 2214 of the rectangular frame 221 is fixed to the upper surface of the sliding support block 25 by bolts or welding. This structural design ensures that multiple battery modules in the same row always maintain the same Y-direction displacement during Y-direction adjustment, that is, there is no relative movement between them. Even in battery packs that are long in the X direction (e.g., more than 1 meter in length), the modules at both ends will not be misaligned due to Y-direction adjustment, ensuring the alignment accuracy of all modules in the battery pack in the Y direction.

[0031] Specifically, the two ends of the adjusting plate 23 are fixedly connected to the sliding support block 25 via lugs. The two ends of the adjusting plate 23 are connected to the sliding support block 25 via lugs. Unlike conventional bolt fastening methods, this solution employs a detachable connection structure with positioning pins and positioning holes. Specifically, the sliding support block 25 has positioning pins on both sides of each rectangular frame 221. The positioning pins are cylindrical or conical pins with their axes extending along the Z direction. Since multiple rectangular frames 221 are arranged along the X direction on the sliding support block 25, and each rectangular frame 221 has one positioning pin on each side (i.e., the side closer to the adjusting plate 23 and the side farther from the adjusting plate 23), each sliding support block 25 has two rows of positioning pins distributed along the X direction, respectively close to its two end faces in the Y direction.

[0032] The adjusting plate 23 has corresponding positioning holes on its lugs. The lugs are ear-shaped protrusions extending outwards from both ends of the adjusting plate 23. When the positioning pins are positioned along the Z-axis, the positioning holes on the lugs are either through holes or blind holes, with their inner diameters fitting with the outer diameters of the positioning pins to facilitate installation and disassembly. The adjusting plate 23 fits onto the positioning pins on the sliding support blocks 25 through the positioning holes on its lugs, thus connecting the adjusting plate 23 to two adjacent sliding support blocks 25. Since the positioning pins on each sliding support block 25 correspond one-to-one with the positioning holes on the lugs of the adjusting plate 23, the position of the adjusting plate 23 in the X-axis is precisely defined, while it remains relatively fixed to the sliding support blocks 25 in the Y-axis. When the sliding support blocks 25 move along the Y-axis, the adjusting plate 23 moves synchronously without the need for additional fasteners. In actual production, when it is necessary to change the module arrangement of the battery pack (e.g., from three modules to four modules) or to assemble different models of modules, the plug-in connection of the positioning pin and the positioning hole is adopted. The operator can replace the adjustment plate 23 in a few seconds without using any tools, which greatly shortens the changeover time of the production line.

[0033] In one alternative implementation, such as Figure 5 , Figure 6 As shown, the battery module positioning fixture also includes an elastic reset assembly 26. Specifically, an elastic reset assembly 26 is provided between two adjacent sets of sliding support blocks 25 along the Y direction. This assembly includes a push rod 261, a slider 262, a stop block 263, and an elastic element 264. The push rod 261 is fixedly mounted on one of the sets of sliding support blocks 25 (referred to as the active side sliding support block 25), and the axis of the push rod 261 extends along the Y direction, with its end facing the adjacent sliding support block 25 (referred to as the driven side sliding support block 25). The push rod 261 can be made of round steel or a screw, and its end is machined into a spherical or hemispherical surface to reduce friction during contact.

[0034] A set of sliders 262 sliding along the Y direction are provided on the driven side sliding support block 25, and a stop block 263 spaced apart from the sliders 262. The sliders 262 are usually housed on a fixed block (not shown) mounted on the surface of the sliding support block 25. The fixed block has a slide rail extending along the Y direction, and the sliders 262 can move on the slide rail, but their range of movement is limited by the limiting structures at both ends. The stop block 263 is fixed to the sliding support block 25, maintaining a preset gap between it and the sliders 262. An elastic element 264 (e.g., a compression coil spring or an elastic rubber column) is provided between the stop block 263 and the sliders 262. One end of the elastic element 264 abuts against the stop block 263, and the other end abuts against the sliders 262. In the free state, the elastic element 264 is slightly pre-compressed, pushing the sliders 262 so that the sliders 262 contact the end face of the slide groove near the push rod 261. At this time, the sliders 262 are at the front end of their stroke.

[0035] The end of push rod 261 extends close to the end of slider 262, but in the initial state (i.e., when no force is applied), there is a small gap (e.g., 0.5mm~2mm) between the end of push rod 261 and the end of slider 262. This gap is to prevent fatigue caused by continuous pressure on elastic element 264 during normal positioning. When the first linear actuator 24 pushes the active-side sliding support block 25 to the driven side via the adjusting plate 23, push rod 261 on the active-side sliding support block 25 first moves a free stroke to eliminate the gap between it and slider 262, and then the end of push rod 261 contacts the end of slider 262. As it continues to move, push rod 261 pushes slider 262 against the elastic force of elastic element 264 towards the stop block 263, thereby compressing elastic element 264. The compressive force of elastic element 264 is transmitted to the driven-side sliding support block 25 through stop block 263, causing the driven-side sliding support block 25 and its battery module to move together. When the thrust of the first linear actuator 24 is removed, the elastic potential energy stored in the elastic element 264 is released, pushing the slider 262 to move in the opposite direction. The slider 262 then pushes the push rod 261 and the active side sliding support block 25 backward. Since there is an elastic reset component 26 between all adjacent sliding support blocks 25, all sliding support blocks 25 will eventually return to their initial dispersed positions.

[0036] During the Y-axis stacking process, pressure is transmitted between adjacent battery modules through the aforementioned elastic reset component 26. This absorbs unevenness on the module end faces caused by manufacturing errors, ensuring that each module is pushed to its reference position in the Y-axis without excessive stress concentration due to local protrusions, thus protecting the battery module casing and internal cells. Furthermore, when adjusting the number of modules or replacing modules, there is no need to manually push back the sliding support frame 22; the elastic reset component 26 automatically returns to its original position, improving operational efficiency. In addition, the presence of the elastic element 264 ensures controllable stacking pressure throughout the Y-axis adjustment process. By selecting elastic elements 264 with different stiffnesses or adjusting the pre-compression amount, the clamping force between adjacent modules can be precisely controlled, which is particularly important for battery pack designs that require a certain pre-compression force between modules.

[0037] Specifically, such as Figure 7As shown, the first linear actuator 24 includes a drive plate 241 and a lead screw and nut transmission pair 242. The lead screw and nut transmission pair 242 consists of a lead screw, a nut, and a power source (e.g., a servo motor) for driving the lead screw to rotate. The lead screw is arranged along the Y-direction, and its two ends are mounted on a fixed support frame 21 or an independent bracket via bearing seats. The nut is threadedly engaged with the lead screw, and when the lead screw rotates, the nut moves linearly along the Y-direction. The drive plate 241 is a metal plate with sufficient length and rigidity, extending along the X-direction. The drive plate 241 is fixedly connected to the nut, and the X-direction extension length of the drive plate 241 at least covers the total X-direction length of all battery module accommodating spaces. That is, if the total length of all rectangular frames 221 arranged in the X-direction is L, then the length of the drive plate 241 should also be close to or greater than L. The height of the drive plate 241 should be aligned with the Y-direction force-bearing area of ​​the adjustment plate 23. Typically, the working surface of the drive plate 241 (i.e. the surface facing the adjustment plate 23) should be directly opposite the side of the adjustment plate 23.

[0038] When the lead screw and nut transmission pair 242 actuates, the nut drives the drive plate 241 to translate along the Y direction. The drive plate 241 simultaneously contacts and pushes all the adjusting plates 23 located on the same outer side in the Y direction. Since the drive plate 241 is an integral component extending along the X direction, the thrust it applies is evenly distributed in the X direction. This avoids the problem of uneven force on the adjusting plates 23 caused by single-point pushing. The lead screw and nut transmission pair 242 has high transmission accuracy and self-locking capability. When the motor stops rotating, if the friction angle of the lead screw pair is less than the helix angle, reverse self-locking can be achieved, meaning the reverse force transmitted by the adjusting plates 23 cannot drive the lead screw to reverse. Therefore, this solution can maintain the positioning state without an additional braking device.

[0039] Specifically, there are two sets of the first linear actuators 24, respectively mounted on both sides of the fixed support frame 21 along the Y direction. The two sets of first linear actuators 24 have identical structures, each including a lead screw and nut transmission pair 242 and a drive plate 241, and are arranged opposite to each other along the Y direction. The two sets of first linear actuators 24 operate synchronously under the command of the control system. More specifically, the two sets of first linear actuators 24 share the same controller, which receives feedback signals from position sensors (such as optical or magnetic scales) to achieve high-precision synchronous control.

[0040] On the outer sides of the leftmost and rightmost sliding support blocks 25 arranged in the Y direction, a set of drive plates 241 are respectively set. When the two sets of actuators work synchronously, the leftmost module is pushed to the right and the rightmost module is pushed to the left, moving towards the middle area. During this process, they push the inner modules in sequence through the adjusting plate 23 and the elastic reset component 26, and finally all modules converge at the Y-direction centerline of the fixture, forming a centered stack. During the double-sided centering drive, the dimensional tolerances of each module are symmetrically distributed to the left and right sides, so that the center of the entire module array coincides with the center of the fixture. When the battery pack housing B is subsequently installed upside down, if the internal partitions of the housing are also symmetrically designed, the centered modules can be more accurately aligned with the corresponding slots inside the housing.

[0041] To further improve the compatibility of the tooling with battery modules of different X-axis dimensions, in one optional embodiment, a second actuating component (not shown in the figure) is provided on the first tray 10, and the blocking block 11 can slide along the X-axis under the action of the second actuating component. Specifically, as shown... Figure 4 As shown, the upper surface of the first tray 10 is provided with multiple guide rails 12 extending along the X direction, and the lower part of each block 11 has a guide groove that mates with the guide rail 12. The second actuation component can be a lead screw adjustment mechanism mounted on the side of the first tray 10, which drives each block 11 to move synchronously through a long lead screw or rack passing through all the block 11, or it can be equipped with an independent micro linear motor for each block 11 or each group of block 11. In a preferred implementation, two block 11s arranged opposite each other along the X direction (i.e., a pair of block 11s used to limit the two ends of the same battery module) are designed as a linkage structure: when the lead screw is adjusted, this pair of block 11 simultaneously moves towards the center or separates to both sides to change the distance between them, thereby adapting to battery modules of different lengths. This distance adjustment can be manually operated by a handwheel or automatically completed by a servo motor.

[0042] When the production line needs to switch to producing battery packs of different sizes, it only needs to input the X-axis length parameter of the target module. The control system automatically drives the second execution component to adjust each pair of barrier blocks 11 to the corresponding spacing, and the assembly of the new product can begin without replacing the first tray 10. At the same time, since the movement of the barrier blocks 11 is along the X-axis, its adjustment process will not affect the reference in the Y and Z directions. Therefore, the adjustment in the three directions is independent and does not interfere with each other.

[0043] This invention also provides a specific embodiment of a battery pack assembly system, which includes the battery module positioning fixture described in any of the above embodiments. Furthermore, the system can also be equipped with conventional automated equipment such as automatic loading and unloading robots, vision guidance systems, conveyor lines, and tightening robots. The battery module positioning fixture, as the core workstation of the system, is responsible for organizing multiple randomly arriving battery modules into a module array with precise X / Y / Z relative positional relationships, providing a reference for subsequent processes such as inverted insertion into the casing, connection, and capping.

[0044] The battery pack assembly system further integrates a flipping fixture 30. This flipping fixture 30 is used for... Figure 8 The component C to be flipped (i.e., the temporary assembly of the battery pack housing B, battery module A and second tray 20) is flipped 180° to change the housing from an inverted state to an open state, thereby facilitating subsequent operations.

[0045] Specifically, such as Figure 9 As shown, the flipping fixture 30 includes: a flipping mounting base 31 for accommodating the component C to be flipped, and a lifting mechanism 32 for controlling the sliding of the flipping mounting base 31 along the Z-axis. The flipping mounting base 31 is typically a frame structure with installation space, the internal dimensions of which match the external dimensions of the component C to be flipped. The lifting mechanism 32 is used to raise the flipping mounting base 31 and the connected component C to a safe height before flipping to avoid collisions during rotation; and to lower it to a working height for easy disassembly after flipping. Depending on different load, accuracy, and automation requirements, the lifting mechanism can be one or a combination of pneumatic cylinders, hydraulic cylinders, and electric push rods. The flipping mounting base 31 is provided with a flipping drive assembly (not shown in the figure) for driving the component C to be flipped to rotate around a horizontal axis. The flipping drive assembly may include a servo motor, a reducer, and a rotating shaft that mates with the connecting flange on the component C to be flipped. The component C to be flipped is fixed to the flipping mounting base 31 by bolts or quick-change clamps, so that it is coaxially connected to the output shaft of the flipping drive assembly.

[0046] Specifically, such as Figure 10As shown, several connecting blocks 27 are fixedly installed on the lower or side of the second tray 20. Positioning holes or slots can be provided on the connecting blocks 27. A support seat 311 is correspondingly provided on the flip mounting base 31, which is used to dock with the connecting blocks 27 of the second tray 20. A third linear actuator 33 (e.g., an electric push rod 261 or a screw jack) is mounted on the flip mounting base 31, and its output end is connected to the support seat 311, controlling the support seat 311 to move relative to the flip mounting base 31 along the Z-axis. When the flip mounting base 31 is lowered to the height of the component C to be flipped via the lifting mechanism 32, the support seat 311 engages with the connecting blocks 27 of the second tray 20 (e.g., via a pin or electromagnetic chuck). Subsequently, the third linear actuator 33 actuates, driving the support seat 311 to move upward, thereby lifting the second tray 20 upward. This lifting action completely separates the second tray 20 from the first tray below it, allowing the flip fixture 30 to perform a flipping operation on the second tray 20, the battery module, and the battery pack housing B. The third linear actuator 33 may be a cylinder, a hydraulic cylinder, or an electric screw jack.

[0047] The flipping fixture 30 works in conjunction with the aforementioned battery module positioning fixture to form a complete process chain from module positioning, module insertion into the housing, and housing flipping. Because the second tray 20 remains fixedly connected to the battery pack housing B during the flipping process, and the second tray 20 itself has a rectangular frame 221 structure that continuously constrains the relative position of the battery module, even after a 180° flip, the module will not shift or fall out of the housing.

[0048] This invention also provides a specific embodiment of a battery pack assembly method. This method utilizes the aforementioned positioning fixture, flipping fixture 30, and related auxiliary equipment to efficiently and accurately assemble the battery module and the battery pack housing B. The method includes the following steps performed sequentially: Step 1: Placement and Y-axis positioning of the battery module A single battery module is held in place by an external clamping mechanism (such as a six-axis robot with flexible grippers) and placed into the respective battery module receiving spaces of the second tray 20. During placement, the operator or vision system should guide the clamping mechanism so that the two terminals (positive and negative terminals) of the battery module are aligned with the first beam 2211 and the second beam 2212 of the rectangular frame 221, respectively. The clamping mechanism is slowly lowered until the terminals are stably seated on the upper surfaces of the first and second beams 2212. Since the upper surfaces of the first and second beams 2212 are precision-machined planes, and their Z-axis height relative to the reference surface of the sliding support block 25 has been pre-calibrated with tooling manufacturing precision, the Z-axis position of the battery module is uniquely determined after the terminals are seated.

[0049] Meanwhile, the third beam 2213 and the fourth beam 2214 of the rectangular frame 221 are located on the lower side of the module body. They do not directly bear the mass of the module, but provide lateral restraint during Y-axis adjustment to prevent the module from rotating around the pole when pushed. The two sets of adjacent blocking blocks 11 on the first tray 10 along the X-axis automatically restrict the X-axis position of each battery module. That is, the two ends of the battery module abut against the sides of the two blocking blocks 11 respectively, completing the X-axis alignment. At this time, the battery module is restrained by the blocking blocks 11 in the X-axis, supported by the first and second beams 2212 in the Z-axis, and can still slide freely in the Y-axis, presenting a state of "X / Z locked, Y-axis floating".

[0050] Subsequently, the Y-axis adjustment components are adjusted. Specifically, if a dual-side drive method is adopted, the two sets of first linear actuators 24 are controlled to move synchronously, causing the battery modules located on both sides of the Y-axis to move towards the central area. Ultimately, all modules are symmetrically distributed at equal intervals with the center line of the tooling as the reference. During the stacking process, since each sliding support block 25 has multiple positioning posts arranged along the X-axis, and the positioning holes on the adjustment plate 23 cooperate with them, the adjustment plate 23 always maintains parallelism with the end face of the sliding support block 25 along the entire X-axis length, thereby ensuring that the thrust is evenly distributed on all rectangular frames 221 and avoiding individual modules from tilting due to uneven force.

[0051] By selecting elastic elements 264 with different stiffnesses, the clamping force during stacking can be controlled to avoid damage to the module end face or the terminal connection structure. After Y-axis positioning is completed, all battery modules are precisely limited in the X-axis by the blocking block 11, maintained in the Y-axis by the stacking pressure, and supported by the first and second beams 2212 in the Z-axis, forming a stable spatial posture.

[0052] Step 2: Inverted installation of battery pack casing B The battery pack housing B is inverted and placed on top of the battery accommodating space, so that the stacked battery modules are partially housed inside the battery pack housing B, forming the component C to be flipped. Specifically, the clamping mechanism grasps the battery pack housing B, with its opening facing downwards, aligning it with the pre-positioned module array below. The housing is slowly lowered, allowing the top of the modules to enter the housing to a certain depth. At this point, the second tray 20, the battery modules located on the second tray 20, and the inverted battery pack housing B together constitute a component C to be flipped.

[0053] Step 3: Transfer and Z-axis separation of component C to be flipped The component C to be flipped is moved to the workstation of the flipping fixture 30. Since there is no fixed connection between the first pallet and the second pallet 20, the entire positioning fixture (including the first and second pallets 20 and their modules and housings) can be transported to the working area of ​​the flipping fixture 30 via AGV or conveyor belt. Upon arrival, the lifting mechanism 32 of the flipping fixture 30 is controlled to lower the flipping mounting base 31 to the area of ​​the component C to be flipped, so that the flipping mounting base 31 is close to the second pallet 20. Then, the flipping mounting base 31 is connected to the second pallet 20: specifically, the support base 311 on the flipping mounting base 31 mates with and locks with the connecting block 27 on the second pallet 20. After the mate is completed, the third linear actuator 33 is controlled to move, driving the support base 311 to move upward along the Z direction, thereby lifting the second pallet 20 upward. As the second pallet 20 rises, the gap between it and the first pallet gradually increases until the second pallet 20 is completely separated from the first pallet. After separation, the first pallet is removed from the working area. After the first tray is removed, the second tray 20 and its attached modules and housing remain suspended by the support base 311. At this time, the second tray 20 is temporarily fixed to the battery pack housing B using screws or quick clamps to ensure that their relative positions remain unchanged during subsequent flipping.

[0054] Step 4: Flipping component C to be flipped The lifting mechanism 32 is controlled to operate, causing the flip mounting base 31 to rise along the Z-axis to a preset safe height (e.g., so that the lowest point of the component C to be flipped is higher than all obstacles). The set height should be at least greater than the flip radius to ensure that the component will not collide with any object during the 180° rotation. After the lifting is in place, the flip drive component is activated, causing the flip mounting base 31 to rotate 180° around the horizontal axis at a constant speed. After the 180° rotation, the orientation of the component C to be flipped becomes: the battery pack housing B is open upwards, and the positioning platform 30 and the second tray 20 are located above the battery pack housing B. At this time, the battery module is located inside the battery pack housing B. Since the original X / Y position of the module is accurate, and the direction of gravity changes during the flipping process but the module is constrained by the rectangular frame 221, the final position of the module inside the housing is highly consistent with the design position.

[0055] Step 5: Removal of the second tray 20 The lifting mechanism 32 is controlled to lower the flip mounting base 31 to a working height that facilitates disassembly. The connection between the second tray 20 and the battery pack housing B is released (e.g., by loosening screws or opening clips). Subsequently, the second tray 20 is removed from the housing by a robotic arm or manually. At this point, all battery modules are precisely assembled inside the battery pack housing B, and the housing is open facing upwards, allowing for direct subsequent processes such as terminal connection, data acquisition harness installation, and top cover sealing.

[0056] This method organically integrates processes such as independent positioning of battery modules, synchronous stacking of multiple modules, pre-assembly with the casing inverted, overall flipping, and removal of the second tray 20, forming a complete assembly process. It utilizes the functional switching of a split tray in different processes: the first tray 10 primarily serves as the X / Y axis reference, while the second tray 20 primarily serves as the module holding and transport function. During the module positioning stage, both work together; during the casing insertion stage, the second tray 20 supports the module as it rises and integrates with the casing; during the flipping stage, the second tray 20 acts as a protective cover and connector; in the final stage, the second tray 20 is removed and reused. This minimizes the number of auxiliary tooling, reducing equipment investment and changeover time. It can be widely applied in automated or semi-automated assembly lines for various power batteries.

[0057] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A battery module positioning fixture, characterized in that, include: The first tray is located on the lower side, and the second tray is located on the upper side of the first tray. The second tray includes a fixed support frame and at least two sets of sliding support frames that are spaced apart along the Y direction and slide on the fixed support frame. The sliding support frame includes at least two sets of rectangular frames to form a battery module accommodating space. The first tray is provided with a plurality of blocking blocks arranged in a matrix and extending along the Z direction. The blocking blocks are used to limit the installation position of the battery module along the X direction. The Y-axis adjustment component includes a first linear actuator disposed outside the battery module accommodating space and an adjustment plate located between adjacent battery module accommodating spaces along the Y-axis; the output end of the first linear actuator can act on the battery module through the adjustment plate to adjust the Y-axis installation position of the battery module.

2. The battery module positioning fixture according to claim 1, characterized in that, The fixed support frame is provided with a slide rail extending along the Y direction. Several rectangular frames arranged along the X direction are slidably connected to the slide rail of the fixed support frame through a set of sliding support blocks. The two ends of the adjustment plate are fixedly connected to the sliding support blocks through lugs.

3. The battery module positioning fixture according to claim 2, characterized in that, An elastic reset assembly 26 is also provided between two adjacent sets of sliding support blocks along the Y direction. It includes a push rod disposed on one set of the sliding support blocks and extending along the Y direction, a slider disposed on the other set of the sliding support blocks and slidable along the Y direction, a stop block spaced apart from the slider, and an elastic element located between the stop block and the slider block; wherein, the end of the push rod extends to the end close to the slider.

4. A battery module positioning fixture according to any one of claims 1-3, characterized in that, The first linear actuator includes a lead screw and nut transmission assembly and a drive plate extending along the X direction. The drive plate is connected to the output end of the lead screw and nut transmission assembly that moves linearly, and the extension length of the drive plate covers the length of the battery module accommodating space along the X direction.

5. A battery module positioning fixture according to claim 1, characterized in that, The first linear actuator consists of two sets, which are respectively installed on both sides of the fixed support frame along the Y direction. The two sets of the first linear actuators act synchronously on the two battery modules located on the outermost side of the Y direction.

6. The battery module positioning fixture according to claim 1, characterized in that, The first tray is provided with a second linear actuator, and the blocking block can slide along the X direction under the action of the second actuator.

7. A battery packaging and assembly system, characterized in that, The battery module positioning fixture according to any one of claims 1-6 further includes a flipping fixture, the flipping fixture including a flipping mounting base for accommodating the component C to be flipped and a lifting mechanism for controlling the flipping mounting base to slide along the Z direction; wherein, the flipping mounting base is provided with a flipping drive component for driving the component C to be flipped to rotate around a horizontal axis.

8. A battery packaging and distribution system according to claim 7, characterized in that, The second tray is provided with a connecting block, and the flip mounting base is provided with a support base connected to the connecting block and a third linear actuator for controlling the support base to move along the Z direction.

9. A battery packaging method, characterized in that, Includes the following steps: Multiple battery modules are placed in the battery module accommodating space of the second tray. Two adjacent sets of the barrier blocks along the X direction restrict the X-direction position of one set of battery modules. The Y-direction adjustment component is adjusted so that the battery modules are stacked along the Y direction to the set position. The battery pack housing B is inverted and placed on the upper side of the battery accommodating space, so that the stacked battery module is partially accommodated inside the battery pack housing B, forming the component C to be flipped. Move the component C to be flipped to the work station where the flipping fixture is located, control the lifting mechanism to lower the flipping mounting base to the area of ​​the component C to be flipped, connect the flipping mounting base to the second tray, and control the second linear actuator to move the second tray upward until the second tray is completely separated from the first tray. Remove the first tray and connect the second tray to the battery pack housing B. The lifting mechanism is controlled to raise the flipping mounting base to a set position, and then the rotation drive component is controlled to rotate the flipping mounting base 180° around the horizontal axis, so as to flip the component C to be flipped. After the lifting mechanism is controlled to lower the flip mounting base to the set position, the connection between the second tray and the battery pack housing B is released.

10. The battery packaging method according to claim 9, characterized in that, Two sets of the first linear actuators are arranged along the Y direction, and the first linear actuators are controlled to operate synchronously, so that the battery modules located on both sides are stacked towards the middle area.

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