Battery cell arrangement method, device, and storage medium

Abstract

The application discloses a battery cell arrangement method and device and a storage medium, relates to the technical field of power batteries, and comprises the following steps: based on effective cavity length, effective cavity width, cell diameter and cell safety center distance, calculating corresponding first total cell layer number and single-row cell number in a straight-row mode, and determining a first candidate total cell number; based on effective cavity length, effective cavity width, cell diameter and cell safety center distance, calculating corresponding second total cell layer number, odd-layer single-layer cell number and even-layer single-layer cell number in at least one plug-in row mode by using a trigonometric function, and determining a second candidate total cell number; comparing the first candidate total cell number with at least one second candidate total cell number, selecting an arrangement mode with the largest total cell number as a target arrangement mode, solving the technical problem that cell arrangement in a battery pack cavity depends on manual experience, leading to low space utilization and difficulty in realizing the maximization of the number of cells, and improving the space utilization.

Description

Technical Field

[0001] This application relates to the field of power battery technology, and in particular to a method, apparatus and storage medium for arranging battery cells. Background Technology

[0002] In the design process of power battery modules, the arrangement of cells within the internal cavities of the battery pack directly determines the volumetric energy density of the battery pack. Current cell arrangement methods primarily rely on the personal experience of structural engineers. They manually draw cell layout diagrams using computer-aided design software, initially selecting an arrangement based on intuition, and then gradually adjusting the spacing or offset through multiple rounds of manual inspection and localized trial and error until an engineering-acceptable solution is obtained. However, this cell arrangement method, highly dependent on human experience, has significant drawbacks. Engineers are limited by their subjective judgment and the limited number of trials, typically only able to try a few arrangements. It is difficult to systematically exhaustively explore and compare the filling effect of different arrangements, resulting in unutilized non-functional gaps within the battery pack. Space utilization cannot reach the theoretically optimal level, limiting the total number of cells that can be accommodated and the volumetric energy density of the battery pack. The above content is only used to help understand the technical solution of this application and does not represent an admission that the above content is prior art. Summary of the Invention

[0003] The main objective of this application is to provide a method, device, and storage medium for arranging battery cells, aiming to solve the technical problem in the prior art where the arrangement of battery cells in the cavity of a battery pack relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of battery cells.

[0004] To achieve the above objectives, this application proposes a method for arranging battery cells, the method comprising: Determine the effective cavity length and effective cavity width for cell layout, as well as the safe center distance between adjacent cell centers and the cell diameter; Based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, the total number of first cell layers and the number of cells in a single row are calculated according to the straight arrangement method, and the total number of first candidate cells under the straight arrangement method is determined. Based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, according to at least one insertion method, the corresponding total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells are calculated using trigonometric functions. The total number of second candidate cells under at least one insertion method is determined based on the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells. Compare the total number of the first candidate cells with the total number of at least one second candidate cell, and select the arrangement with the largest total number of cells as the target arrangement. Based on the target arrangement, calculate the center coordinates of each cell within the effective cavity and generate the corresponding cell coordinate set.

[0005] In one embodiment, the step of determining the effective cavity length and effective cavity width for cell layout, and the safe center distance between adjacent cell centers, includes: Obtain the original dimensional parameters of the internal cavity of the battery pack, including cavity length, cavity width, cell diameter, cell safety spacing, and reserved installation space. The cavity length and cavity width are subtracted based on the reserved installation space dimensions to obtain the effective cavity length and effective cavity width for cell layout; The cell diameter is added to the cell safety spacing to obtain the cell safety center distance between the centers of adjacent cells.

[0006] In one embodiment, the step of calculating the total number of first cell layers and the number of cells in a single row according to the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, and determining the total number of first candidate cells under the straight-line arrangement, includes: Subtracting the cell diameter from the effective cavity width and dividing by the cell safety center distance, then rounding the resulting quotient down and adding one, yields the total number of first cell layers that can be arranged along the vertical axis. Subtracting the cell diameter from the effective cavity length and dividing by the cell safety center distance, then rounding the resulting quotient down and adding one, yields the number of cells in a single row. Multiply the total number of layers of the first cell by the number of cells in a single row to obtain the total number of first candidate cells in the straight-line arrangement.

[0007] In one embodiment, the step of calculating the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells using trigonometric functions based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, according to at least one insertion method, includes: Select a staggered angle, wherein the staggered angle is 45° or 60°; Multiply the cell safety center distance by the cosine of the staggered angle to obtain the even-numbered layer lateral offset, and multiply the cell safety center distance by the sine of the staggered angle to obtain the interlayer longitudinal center distance. Subtracting the cell diameter from the effective cavity width and dividing by the longitudinal center distance between layers, then rounding the resulting quotient down and adding one, yields the total number of second cell layers that can be arranged along the longitudinal axis. The total number of layers in the second battery cell is divided into odd-numbered layers and even-numbered layers; Subtracting the cell diameter from the effective cavity length and dividing by the cell safety center distance, then rounding the resulting quotient down and adding one, yields the number of odd-numbered single-layer cells. Subtract the cell diameter and the lateral offset of the even-numbered layers from the effective cavity length, divide the resulting difference by the cell safety center distance, round down, and add one to obtain the number of cells in the even-numbered single layer.

[0008] In one embodiment, the total number of layers of the second battery cell includes an odd number of battery cell layers and an even number of battery cell layers. The step of determining the total number of second candidate battery cells under at least one power strip method based on the total number of layers of the second battery cell, the number of single-layer cells in the odd number of layers, and the number of single-layer cells in the even number of layers includes: For each type of power strip, the product of the number of odd-numbered battery cells and the number of single-layer cells in the odd-numbered layer is added together with the product of the number of even-numbered battery cells and the number of single-layer cells in the even-numbered layer to obtain the total number of second candidate cells for the corresponding power strip type. The at least one type of insertion method includes a method in which the staggered angle is 45° and the arrangement is along the horizontal axis, a method in which the staggered angle is 45° and the arrangement is along the vertical axis, a method in which the staggered angle is 60° and the arrangement is along the horizontal axis, and a method in which the staggered angle is 60° and the arrangement is along the vertical axis.

[0009] In one embodiment, after determining the total number of second candidate cells under at least one socket configuration based on the total number of layers of the second cell, the number of cells in the odd-numbered single-layer configuration, and the number of cells in the even-numbered single-layer configuration, the method further includes: For each type of power strip, calculate the space utilization rate corresponding to that power strip type; If the space utilization rate is less than a preset threshold, the first evenly divided gap corresponding to the horizontal axis direction is calculated based on the effective cavity length, the cell diameter and the number of single-layer cells, and the number of single-layer cells is the number of odd-numbered single-layer cells and the number of even-numbered single-layer cells. Add the first evenly divided gap to the cell safety center distance to obtain the updated horizontal axis stacking center distance; Based on the cell safety center distance and the updated horizontal stacking center distance, the updated interlayer longitudinal center distance and the updated even-numbered layer horizontal offset are solved using Heron's formula. Based on the updated horizontal stacking center distance, the updated interlayer longitudinal center distance, and the updated even-numbered layer horizontal offset, the total number of second cell layers, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers that the effective cavity can accommodate are recalculated.

[0010] In one embodiment, after the step of recalculating the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells that the effective cavity can accommodate, the method further includes: Based on the effective cavity width, the cell diameter, and the total number of layers in the second cell, calculate the second evenly divided gap corresponding to the longitudinal axis direction; Add the second evenly divided gap to the first updated longitudinal center distance between layers to obtain the second updated longitudinal center distance between layers; Determine whether the longitudinal center distance between layers after the second update is less than the safe center distance of the battery cell; If the longitudinal center distance between layers after the second update is less than the safe center distance of the cells, it is determined that the vertical spacing between cells in the odd and even layers is insufficient. The offset of the even-numbered layers in the horizontal direction and the stacking center distance in the horizontal direction after the second update are calculated using the Heron formula. Based on the second updated horizontal stacking center distance, the second updated interlayer longitudinal center distance, and the second updated even-numbered layer horizontal offset, the total number of second cell layers that the effective cavity can accommodate, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers are recalculated to obtain the second updated total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers.

[0011] In one embodiment, after the step of recalculating the total number of second cell layers, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers based on the second-updated horizontal stacking center distance, the second-updated inter-layer longitudinal center distance, and the second-updated horizontal offset of even-numbered layers, to obtain the second-updated total number of second cell layers, the second-updated number of single-layer cells in odd-numbered layers, and the second-updated number of single-layer cells in even-numbered layers, the method further includes: Determine whether the number of odd-numbered single-layer cells after the second update is consistent with the number of even-numbered single-layer cells after the second update; If they are inconsistent, when the number of odd-numbered single-layer cells after the second update is greater than the number of even-numbered single-layer cells after the second update, the first evenly divided gap is multiplied by the product of the number of odd-numbered single-layer cells after the second update minus one, and half of the cell safety center distance is added. The resulting sum is then divided by the difference between the number of even-numbered single-layer cells after the second update minus 0.5 to obtain the updated evenly divided gap in the horizontal direction. When the number of odd-numbered single-layer cells after the second update is less than the number of even-numbered single-layer cells after the second update, the first evenly divided gap is multiplied by the product of the number of even-numbered single-layer cells after the second update minus 0.5, and half of the cell safety center distance is added. The resulting sum is then divided by the difference between the number of odd-numbered single-layer cells after the second update minus one to obtain the updated horizontal axis evenly divided gap. The first evenly divided gap is replaced with the updated horizontal axis evenly divided gap, and the overall arrangement is re-iterated. The total number of second cell layers, the number of odd-numbered single-layer cells and the number of even-numbered single-layer cells that the effective cavity can accommodate are recalculated to obtain the total number of second cell layers, the number of odd-numbered single-layer cells and the number of even-numbered single-layer cells after three updates.

[0012] Furthermore, to achieve the above objectives, this application also proposes a battery cell arrangement device, the battery cell arrangement device comprising: The cavity preprocessing module is used to determine the effective cavity length and effective cavity width for cell layout, as well as the safe center distance and cell diameter between adjacent cell centers; The straight-line quantization and calculation module is used to calculate the total number of first cell layers and the number of cells in a single row according to the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, and to determine the total number of first candidate cells under the straight-line method. The plug-in quantization and calculation module is used to calculate the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells according to at least one plug-in method based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, using trigonometric functions. The module also determines the total number of second candidate cells under at least one plug-in method based on the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells. The optimal selection module is used to compare the total number of the first candidate battery cells with the total number of at least one second candidate battery cells, and select the arrangement with the largest total number of battery cells as the target arrangement. The cell coordinate generation module is used to calculate the center coordinates of each cell in the effective cavity according to the target arrangement, and generate the corresponding cell coordinate set.

[0013] In addition, to achieve the above objectives, this application also proposes a battery cell arrangement device, the device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the battery cell arrangement method described above.

[0014] In addition, to achieve the above objectives, this application also proposes a storage medium, which is a computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, it implements the steps of the battery cell arrangement method described above.

[0015] In addition, to achieve the above objectives, this application also provides a computer program product, which includes a computer program that, when executed by a processor, implements the steps of the battery cell arrangement method described above.

[0016] The one or more technical solutions proposed in this application have at least the following technical effects: Determining the effective cavity length and effective cavity width for cell layout, as well as the safe center distance and diameter between adjacent cells. Based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, calculating the total number of first cell layers and the number of cells in a single row according to the straight-line arrangement, and determining the total number of first candidate cells under the straight-line arrangement; Based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, calculating the total number of second cell layers, the number of cells in odd-numbered single layers, and the number of cells in even-numbered single layers according to at least one insertion arrangement using trigonometric functions, and determining the total number of second candidate cells under at least one insertion arrangement based on the total number of second cell layers, the number of cells in odd-numbered single layers, and the number of cells in even-numbered single layers, thus covering the capacity of misaligned layouts that are difficult to manually calculate. By comparing the total number of first candidate cells with the total number of at least one second candidate cell, the arrangement with the largest total number of cells is selected as the target arrangement to maximize the number of cells accommodated. Based on the target arrangement, the center coordinates of each cell in the effective cavity are calculated according to the arrangement rules of the target arrangement, and the corresponding set of cell coordinates is generated. The abstract arrangement is transformed into precise data, which solves the technical problem in the prior art that the arrangement of cells in the battery pack cavity relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of cells. This reduces the ineffective blank space in the battery cavity and improves the space utilization rate. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1This is a flowchart illustrating the cell arrangement method for the battery in this application, as provided in Embodiment 1. Figure 2 This application provides a schematic diagram of a battery pack structure; Figure 3 A schematic diagram of a rectangular cavity cell arrangement provided in this application; Figure 4 This application provides a schematic diagram of the straight-line arrangement parameters and odd / even layering of a cuboid cavity. Figure 5 A schematic diagram illustrating the effect of a straight-line battery cell arrangement provided in this application; Figure 6 A schematic diagram of two types of plug-in arrangements (arranged along the length and width respectively) of a battery cell at 45° provided for this application; Figure 7 A schematic diagram of two types of plug-in arrangements (arranged along the length and width respectively) of a battery cell at 60° provided in this application; Figure 8 A schematic diagram of the plug layout parameters and odd / even layer labeling when the cell misalignment angle is 45°, provided for this application; Figure 9 A schematic diagram of the plug layout parameters and odd / even layer labeling when the cell misalignment angle is 60°, provided for this application; Figure 10 This application provides a schematic diagram illustrating the battery cell arrangement effect under a power strip configuration. Figure 11 This application provides a schematic diagram of the arrangement parameters of a battery cell after expansion along the horizontal axis. Figure 12 This application provides a schematic diagram of the arrangement parameters of a battery cell after expansion along the longitudinal axis. Figure 13 This application provides a comparative diagram of layout effect and space utilization. Figure 14 This application provides a schematic diagram comparing the dimensions of the cavity before and after the adjustment of its profile. Figure 15 A schematic diagram illustrating the arrangement result when expanding outward by 5mm or contracting inward by 5mm, as provided in this application; Figure 16 A schematic diagram showing the cell arrangement result after cavity contour adjustment under a plug-in method provided in this application; Figure 17 This is a schematic diagram of the device structure of the hardware operating environment involved in the battery cell arrangement method in the embodiments of this application. Detailed Implementation

[0020] It should be understood that the specific embodiments described herein are merely illustrative of the technical solutions of this application and are not intended to limit this application.

[0021] To better understand the technical solution of this application, a detailed description will be provided below in conjunction with the accompanying drawings and specific implementation methods.

[0022] The main solution of this application embodiment is as follows: Determine the effective cavity length and effective cavity width for cell layout, as well as the safe center distance and diameter between adjacent cell centers; based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, calculate the total number of first cell layers and the number of cells in a single row according to the straight-line arrangement, and determine the total number of first candidate cells under the straight-line arrangement; based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, calculate the corresponding total number of second cell layers, the number of cells in odd-numbered layers, and the number of cells in even-numbered layers using trigonometric functions according to at least one insertion method, and determine the total number of second candidate cells under at least one insertion method based on the total number of second cell layers, the number of cells in odd-numbered layers, and the number of cells in even-numbered layers; compare the total number of first candidate cells with the total number of at least one second candidate cell, and select the arrangement with the largest total number of cells as the target arrangement; calculate the center coordinates of each cell within the effective cavity according to the target arrangement, and generate the corresponding cell coordinate set.

[0023] In this embodiment, for ease of description, the following description will focus on the battery cell arrangement system.

[0024] With the rapid development of electric vehicles and renewable energy storage systems, the performance and ease of maintenance of power battery modules, as their core energy storage components, are becoming increasingly important. Currently, the specific implementation process for the arrangement of lithium-ion cells within the battery pack during the design of power battery modules is as follows: First, structural engineers, based on experience, initially select one or several arrangement methods according to the internal contour dimensions of the battery pack casing, the size and shape of individual cells, the spacing between cells, and the location of electrical connection interfaces. Then, computer-aided design software is used to manually draw the cell layout diagram, initially placing the cell model and reserving space for insulating separators and busbar connections. Next, manual checks are conducted to check for mechanical interference, excessive gaps, or inability to install connectors. If problems are found, the arrangement spacing or overall offset is adjusted. Finally, after multiple rounds of manual adjustments and local trial and error, an engineering-acceptable layout scheme is formed. The entire process highly relies on the engineer's intuitive judgment and iterative iteration.

[0025] However, this traditional layout method has the following significant shortcomings: First, limited by the subjectivity of human experience and the limited number of trials, engineers can only make local fine-tuning in a limited number of arrangements. They cannot systematically explore multiple possible layout topologies for a given battery pack cavity size, leading to non-functional gaps inside the battery pack. This makes it difficult to achieve the theoretically optimal space utilization, directly limiting the number of cells that can be loaded and thus affecting the volumetric energy density of the battery pack. Second, the design efficiency is low. When facing an increase in the number of cells or irregular battery pack shapes, each adjustment requires manual re-layout modification, resulting in a lengthy design cycle and poor solution versatility, making it difficult to quickly reuse solutions across different projects. Third, the manual approach is essentially a local search. Engineers often make fine-tuning based on familiar arrangements, easily getting trapped in local optima, making it difficult to simultaneously achieve global optimization for multiple objectives such as space utilization, structural strength, and electrical safety, especially in high-capacity, multi-cell integration scenarios. Furthermore, it has weak adaptability to irregularly shaped battery packs, failing to quickly generate optimized layouts that meet assembly process requirements and facilitate later maintenance. The aforementioned shortcomings mean that traditional methods can no longer meet the urgent needs of modern power battery modules for high energy density, short design cycles, and intelligent layout.

[0026] This application provides a solution. First, it determines the effective cavity length and effective cavity width for cell placement, as well as the safe center distance and diameter between adjacent cells. Based on this, it quickly obtains the total number of first cell layers and the number of cells per row using simple integer division operations in a straight-line arrangement, and multiplies them to obtain the total number of first candidate cells. Simultaneously, it accurately calculates the total number of second cell layers after misalignment using trigonometric functions for at least one insertion method, as well as the number of cells per layer in odd and even layers due to the different effective usable lengths of odd and even layers caused by offset. This yields the total number of second candidate cells for each insertion method, systematically covering the entire process in a single calculation. The method provides a candidate arrangement space that allows for both straight-line and multiple socket arrangements, overcoming the limitation of manual methods that can only explore a few arrangements. Then, using the total number of cells as the sole objective comparison indicator, the total number of the first candidate cells is compared with the total number of all second candidate cells, and the arrangement corresponding to the maximum value is selected as the target arrangement. This transforms the judgment of which arrangement is better from subjective experience into a deterministic numerical decision, ensuring that the obtained target arrangement achieves a global maximum number of cells under given constraints, rather than a locally acceptable number. Finally, the center coordinates of each cell are automatically calculated based on the target arrangement, generating a complete coordinate set and directly outputting accurate data for downstream design or manufacturing. The cell arrangement method provided in this application replaces local manual trial and error with global quantitative calculation, simultaneously calculating multiple arrangement schemes and selecting the best one. It maximizes the number of cells accommodated under a fixed cavity size, fundamentally reducing non-functional gaps, thereby effectively solving the technical problems of low space utilization and difficulty in reaching the upper limit of the number of cells in manual arrangement.

[0027] It should be noted that the executing entity in this embodiment can be a computing service device with data processing, network communication, and program execution functions, such as a tablet computer, personal computer, or mobile phone, or a battery cell arrangement device capable of performing the above functions. The following description uses a battery cell arrangement system as an example to illustrate this embodiment and the subsequent embodiments.

[0028] Based on this, embodiments of this application provide a method for arranging battery cells, referring to... Figure 1 , Figure 1 This is a flowchart illustrating the first embodiment of the battery cell arrangement method of this application.

[0029] In this embodiment, the battery cell arrangement method includes steps 101-105: Step 101: Determine the effective cavity length and effective cavity width for cell layout, as well as the safe center distance between adjacent cell centers and the cell diameter.

[0030] The hardware structure corresponding to the cell arrangement in this application comprises three components: a regular rectangular cavity, cylindrical cells, and brackets and BMS board auxiliary components. The overall internal cavity of the battery pack serves as the total installation space for all components. The standard rectangular cavity is the core area for placing the cylindrical cells. The brackets and BMS board are uniformly located at the edges of the rectangular cavity. During the design phase, a dedicated installation area for auxiliary components is pre-defined within the overall space. This dedicated installation area for auxiliary components is completely separated from the cell arrangement area and does not overlap, thus avoiding structural interference from the outset. The cylindrical cell is a single cylindrical unit, with its axis placed vertically along the height of the battery pack. All cells are arranged only within the effective rectangular space formed after deducting the areas reserved for the brackets and BMS. The arrangement is divided into two standardized rules: straight-line and plug-in. After the arrangement is completed, a preset safety gap is maintained between any two adjacent cells. The complete cell array is neatly arranged within the effective rectangular outline. The boundaries between the cavity, cylindrical cells, and edge auxiliary components are clear, and there is no mechanical collision interference between components after assembly. The overall structure can be found in [reference needed]. Figure 2 A schematic diagram of the battery pack structure is shown below. Figure 2 As shown. The automatic calculation of the number of all battery cells and the coordinates of each cell location in this application is based on a two-dimensional cross-section of the rectangular cell arrangement, without involving numerical calculations of the height dimension. During the design process, the original cavity of the battery pack is first extracted, and the space occupied by edge supports and the BMS is removed, resulting in a standard rectangular effective cavity used only for cell placement. (Refer to...) Figure 3 , Figure 3 This is a schematic diagram of a rectangular cavity cell arrangement. The effective cavity length and effective cavity width are extracted to form a planar cross-section, corresponding to... Figure 3The area highlighted in red on the left is simplified into a rectangular outline, which serves as the baseline calculation boundary for the automatic layout algorithm of this application. Within this rectangular baseline boundary, straight-line calculation and various interlocking calculation processes can be executed respectively to calculate the total number of cells that can be accommodated under the two layout forms. The total number of cells loaded in different layout schemes is automatically compared, and the layout with the most cells is selected as the target layout scheme. Then, according to the geometric rules of the selected layout, the planar center coordinates of each cylindrical cell are calculated one by one to generate a complete set of cell coordinates. The cell layout visualization modeling is completed directly in the drawing software based on the coordinate data. The entire process relies on standardized geometric calculations to replace the traditional manual drag-and-drop trial and error layout, maximizing the capacity of cells within the effective cavity range limited by the hardware structure and improving the cavity space utilization efficiency.

[0031] Specifically, the effective cavity length and effective cavity width refer to the actual rectangular area available for arranging the cell array within the original cavity of the battery pack after deducting the reserved installation area for auxiliary structural components such as brackets and BMS boards, as well as the minimum safe boundary from the cell center to the cavity wall. The effective cavity length and effective cavity width are not equal to the internal contour dimensions of the battery pack casing, but rather the net usable dimensions after constraint stripping. The cell diameter is the outer diameter of the cylindrical cell body and is a fundamental geometric parameter determining the space occupied by a single cell. The safe center distance between cells is the minimum distance that must be maintained between the centers of two adjacent cells; the safe center distance is equal to the cell diameter plus the sum of the cell safety spacing.

[0032] In some embodiments, the original length and width dimensions of the battery pack's complete cavity are read, and the required single-sided installation width for the bracket and BMS board on all four sides of the cavity is retrieved. The reserved widths for the auxiliary components on the left, right, top, and bottom sides are deducted in both the original length and width directions to complete spatial partitioning and isolation, retaining only the rectangular area in the middle without component obstruction. The length and width of this rectangle are calculated, i.e., the effective cavity length and effective cavity width. Next, the specifications of the selected cylindrical cells are read, and the outer diameter of the cell cross-section is extracted as the cell diameter. The minimum reserved gap between cells, i.e., the cell safety distance, is set according to the product's insulation and heat dissipation design requirements. The cell diameter is added to the cell safety distance to obtain a fixed cell safety center distance. The calculated effective cavity length and width, the read cell diameter, and the calculated cell safety center distance are uniformly stored as standardized input parameters and completely transferred to the subsequent calculation process of the number of cells in the straight-line and plug-in configurations, serving as fixed reference data for all geometric operations.

[0033] Optionally, the steps of determining the effective cavity length and effective cavity width for cell layout, as well as the safe center distance between adjacent cells, include: Obtain the original dimensional parameters of the internal cavity of the battery pack, including cavity length, cavity width, cell diameter, cell safety spacing, and reserved installation space. The cavity length and cavity width are deducted based on the reserved installation space dimensions to obtain the effective cavity length and effective cavity width for cell installation. Add the cell diameter to the cell safety spacing to obtain the cell safety center distance between adjacent cells.

[0034] Specifically, the safe spacing between battery cells is the gap reserved between the outer walls of two battery cells for heat dissipation, insulation, and to offset the expansion of the battery cells during charging and discharging. This is the minimum clearance required by the manufacturing process. The reserved installation space is the width of one side of the cavity around which the BMS board, mounting brackets, and wiring harnesses are placed. Battery cells are not allowed to be installed within the reserved installation space.

[0035] For example, the original dimensional parameters of the internal cavity of the battery pack are obtained. These original dimensional parameters include at least the cavity length, cavity width, cell diameter, cell safety spacing, and reserved installation space. After obtaining these original dimensional parameters, the cavity length and cavity width are subtracted according to the reserved installation space. Specifically, the effective cavity length is equal to the original cavity length minus the sum of all reserved installation spaces in the length direction, and the effective cavity width is equal to the original cavity width minus the sum of all reserved installation spaces in the width direction. Through this subtraction, the installation areas of auxiliary structural components such as brackets and BMS boards are delineated from the original cavity, resulting in an effective cavity length and effective cavity width used only for cell layout. This effective cavity maintains a regular cuboid shape and serves as the reference boundary for subsequent layout calculations. Simultaneously, the cell diameter and cell safety spacing are added to obtain the cell safety center distance between adjacent cell centers. This safety center distance is the only core control parameter for determining whether adjacent cells interfere in subsequent layout calculations; the distance between the centers of any two adjacent cells must not be less than this safety center distance. By determining the effective cavity length, effective cavity width, and safe center distance between cells, the physical boundaries (effective cavity length and effective cavity width) and the rigid constraints (safe center distance) for cell arrangement are clarified, providing standardized input data for subsequent automated calculations of straight-through and plug-in arrangements. By accurately recording and calculating the original cavity dimensions and the dimensions occupied by auxiliary structural components mathematically, the traditional manual measurement and estimation methods are completely replaced, ensuring the accuracy and consistency of all subsequent arrangement calculations. This provides standardized data input for subsequent automated arrangement calculations, enabling the overall arrangement method to be quickly transferred and reused across different battery pack projects.

[0036] Step 102: Based on the effective cavity length, effective cavity width, cell diameter, and cell safety center distance, calculate the total number of first cell layers and the number of cells in a single row according to the straight arrangement method, and determine the total number of first candidate cells under the straight arrangement method.

[0037] Specifically, the straight-line arrangement involves the cells arranged in a rectangular array with strictly aligned rows and columns within the effective cavity cross-section. This means that the centers of all cells are collinear along both the length (X-axis) and width (Y-axis), with no misalignment or offset between adjacent rows and columns. This is the most basic and regular arrangement. After obtaining the effective cavity length and width, the safe center distance between adjacent cells, and the cell diameter, a coordinate system is defined within the effective cavity. The X-axis runs along the cavity length, and the Y-axis runs along the cavity width. The corresponding coordinate system definition, X / Y center distance parameters, and straight-line odd-even layer alignment structure are as follows: Figure 4 As shown, Figure 4 This is a schematic diagram illustrating the straight-line arrangement parameters and odd / even layering of a cuboid cavity. The number of cells per row is the maximum number of cells that can be accommodated in a single row within the effective cavity, assuming the cell safety center distance constraint is met. In this application, the length direction is the horizontal axis. The total number of first cell layers is the maximum number of rows (layers) that can be arranged in a straight-line manner within the effective cavity, assuming the cell safety center distance constraint is met. In this application, the width direction is the vertical axis. The total number of first candidate cells is the total capacity of cells in the straight-line arrangement, equal to the product of the number of cells per row and the total number of first cell layers, serving as a benchmark candidate value for subsequent comparison with plug-in solutions.

[0038] In some embodiments, the safe center distance between battery cells is first used as the longitudinal arrangement interval. The effective cavity width is subtracted from the reserved size of the battery cell boundary on one side, and then divided by the safe center distance between battery cells. The result is rounded up and then added to obtain the total number of layers of the first battery cell. Next, the number of cells in a single layer is calculated. First, it is determined whether the effective cavity length is greater than the battery cell diameter. If it is not satisfied, the number of cells in a single layer is directly determined to be zero. If it is satisfied, the effective cavity length is divided by the safe center distance between battery cells, rounded up, and then added to obtain the number of cells in a single row. In the straight arrangement mode, the number of cells in odd-numbered layers and even-numbered layers is the same. Then, the total number of layers of the first battery cell can be split into the number of odd-numbered layers and the number of even-numbered layers. The two types of layer numbers are multiplied by the number of cells in a single row and added together. The sum is the total number of first candidate cells in the straight arrangement mode. This value is stored uniformly and used for subsequent comparison with the total number of candidate cells in the power strip to select the optimal arrangement.

[0039] Optionally, the steps of calculating the total number of first cell layers and the number of cells in a single row according to the direct arrangement method based on the effective cavity length, effective cavity width, cell diameter, and cell safety center distance, and determining the total number of first candidate cells under the direct arrangement method include: Subtract the cell diameter from the effective cavity width, divide by the cell safety center distance, round down the resulting quotient, and add one to obtain the total number of first cell layers that can be arranged in the vertical direction. Subtract the cell diameter from the effective cavity length, divide by the cell safety center distance, round down the resulting quotient, and add one to get the number of cells in a single row. Multiply the total number of layers of the first cell by the number of cells in a single row to obtain the total number of first candidate cells in the straight-line arrangement.

[0040] Specifically, in the straight-line arrangement, the battery cells are arranged in a neat, perfectly aligned row and column configuration within the effective cavity, with a fixed center-to-center distance between adjacent rows and columns. First, the effective cavity width is subtracted from the battery cell diameter. The difference is then divided by the center-to-center distance, rounded down, and incremented by one to obtain the total number of first-order battery cell layers that can be arranged along the vertical axis. By subtracting the battery cell diameter, a space of half a battery cell diameter is reserved at the two boundaries along the cavity width to ensure that the solid portion of the edge cells does not exceed the boundaries of the effective cavity. Similarly, the effective cavity length is subtracted from the battery cell diameter, divided by the center-to-center distance, rounded down, and incremented by one to obtain the number of cells per row. After these calculations, the total number of first-order battery cell layers is multiplied by the number of cells per row to obtain the total number of first-order candidate cells in the straight-line arrangement. This product represents the total number of cells that can be accommodated in the effective cavity in the straight-line arrangement. For example, when the effective cavity length is 200mm, the width is 300mm, the cell diameter is 21.5mm, and the cell safety spacing is 1mm (i.e., the cell safety center distance is 22.5mm), the calculation process for the total number of first cell layers that can be arranged in the longitudinal direction is as follows: 300 minus 21.5 equals 278.5, divided by 22.5 equals 12.377, rounded down to 12, and added to get 13 layers; the calculation process for the number of cells in a single row is as follows: 200 minus 21.5 equals 178.5, divided by 22.5 equals 7.933, rounded down to 7, and added to get 8 cells; the final total number of cells that can be arranged in the straight arrangement is 13 multiplied by 8 equals 104 cells.

[0041] After obtaining the number of layers and the number of cells in each layer, the remaining space dimensions in the effective cavity length and width directions can be further calculated. Then, the center coordinates of all cells can be calculated individually based on their row and column positions, generating a set of cell coordinates for subsequent visualization. The arrangement effect can be as follows: Figure 5As shown. When the total number of battery cells does not meet the product design requirements, the cavity boundary can be expanded or contracted by adjusting the contour change parameters. Under the adjusted effective boundary, the same straight-line calculation rules are used to recalculate the layout results until a layout scheme that meets the design requirements is obtained.

[0042] Step 103: Based on the effective cavity length, effective cavity width, cell diameter, and cell safety center distance, calculate the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells using trigonometric functions according to at least one insertion method. Then, determine the total number of second candidate cells under at least one insertion method based on the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells.

[0043] Specifically, the power strips employ a staggered arrangement scheme, including two basic angle schemes: a 60° honeycomb staggered arrangement and a 45° staggered arrangement. Each angle can be further subdivided into two types: arrangement along the length of the cavity and arrangement along the width of the cavity. At least one of the aforementioned power strip methods includes arrangements with a staggered angle of 45° along the horizontal axis, arrangements with a staggered angle of 45° along the vertical axis, arrangements with a staggered angle of 60° along the horizontal axis, and arrangements with a staggered angle of 60° along the vertical axis. (See reference...) Figure 6 and Figure 7 , Figure 6 The diagram shows two different battery cell layouts (arranged along length and width, respectively) at a 45° angle. Figure 7 This diagram illustrates two battery cell layouts at 60° (arranged along length and width, respectively). The total number of battery cell layers is the maximum number of layers that can be accommodated within the effective cavity width along the longitudinal axis (Y-direction) under the plug-in layout, while satisfying the trigonometric function layer spacing constraints. The number of cells per layer in odd-numbered layers is the number of cells that can be accommodated in the horizontal direction of layers 1, 3, 5... (odd-numbered layers), with the left boundary of the cavity wall as the starting alignment reference. The number of cells per layer in even-numbered layers is the number of cells that can be accommodated in the horizontal direction of layers 2, 4, 6... (even-numbered layers). The total number of second candidate cells is the sum of the number of cells in all layers under the plug-in layout, obtained by adding the total number of cells in odd-numbered layers to the total number of cells in even-numbered layers.

[0044] In some embodiments, under the insertion method, odd-numbered layers of cells remain laterally aligned without offset, while even-numbered layers are laterally offset by the same amount, forming a staggered arrangement. The insertion method includes two angle schemes: 60° staggered arrangement and 45° staggered arrangement. Each angle can be further divided into two types: arrangement along the cavity length direction and arrangement along the cavity width direction, resulting in a total of four insertion sub-schemes. For any insertion sub-scheme, firstly, based on the set staggered angle, two key parameters are calculated using trigonometric functions: the lateral offset of even-numbered layers and the longitudinal center distance between layers. The lateral offset of even-numbered layers equals the cell safety center distance multiplied by the cosine of the arrangement angle; while the longitudinal center distance between layers equals the cell safety center distance multiplied by the sine of the arrangement angle. Next, the effective cavity width is subtracted from the cell diameter, divided by the longitudinal center distance between layers, rounded down, and then incremented by one to obtain the total number of layers in the second cell. Then, the total number of layers in the second cell is divided into odd-numbered layers and even-numbered layers, and their number of layers is counted separately. Next, the number of single-layer cells in odd-numbered and even-numbered layers is calculated. The number of single-layer cells in odd-numbered layers is equal to the effective cavity length minus the cell diameter, divided by the safe center distance of the cells, rounded down, and then incremented by one. The number of single-layer cells in even-numbered layers is equal to the effective cavity length minus the cell diameter minus the lateral offset of the even-numbered layers, divided by the safe center distance of the cells, rounded down, and then incremented by one. Finally, the product of the number of odd-numbered layers multiplied by the number of single-layer cells in odd-numbered layers and the product of the number of even-numbered layers multiplied by the number of single-layer cells in even-numbered layers are added to obtain the total number of second candidate cells for this power strip sub-scheme. The total number of second candidate cells for each of the four power strip sub-schemes is calculated separately for subsequent comprehensive comparison and selection with the straight-line method. By accurately solving the misaligned geometric parameters using trigonometric functions, the upper limit of the battery cell capacity of the power strip is fully calculated. The scattered cavity space that cannot be utilized by straight-line power strips is explored, and another set of candidate values ​​is generated. This provides complete power strip reference data for the program to compare the loading capacity of straight-line power strips and various types of power strips and select the maximum number of battery cells to maximize the arrangement, which helps to further improve the utilization rate of cavity space.

[0045] Optionally, the steps of calculating the total number of layers, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers using trigonometric functions based on the effective cavity length, effective cavity width, cell diameter, and cell safety center distance, according to at least one insertion method, include: Select a staggered angle, which can be 45° or 60°; Multiplying the safe center distance of the battery cells by the cosine of the staggered angle yields the lateral offset of even-numbered layers, and multiplying the safe center distance of the battery cells by the sine of the staggered angle yields the longitudinal center distance between layers. Subtract the cell diameter from the effective cavity width, divide by the longitudinal center distance between layers, round down the resulting quotient, and add one to obtain the total number of second cell layers that can be arranged in the longitudinal direction. The total number of layers in the second battery cell is divided into odd-numbered layers and even-numbered layers; Subtract the cell diameter from the effective cavity length, divide by the cell safety center distance, round down the resulting quotient, and add one to obtain the number of odd-numbered single-layer cells. Subtract the cell diameter from the effective cavity length and the lateral offset of the even-numbered layers. Divide the resulting difference by the safe center distance of the cells, round down, and add one to obtain the number of cells in a single even-numbered layer.

[0046] Specifically, the lateral offset of even-numbered layers is the distance the entire even-numbered layer of cells is translated along the horizontal axis (X-direction) relative to the odd-numbered layers. Numerically, the lateral offset of even-numbered layers is equal to the cell safety center distance multiplied by the cosine of the stagger angle. The longitudinal center distance between layers is the projected distance between the centers of two adjacent cell layers along the vertical axis (Y-direction), numerically equal to the cell safety center distance multiplied by the sine of the stagger angle. (Reference) Figure 8 and Figure 9 , Figure 8 This is a schematic diagram showing the socket layout parameters and odd / even layer labeling when the battery cells are staggered at a 45° angle. Figure 9 This is a schematic diagram showing the socket layout parameters and odd / even layer labeling when the battery cells are staggered at a 60° angle. Figure 8 and Figure 9 In this context, sd_stack_X represents the horizontal offset of even-numbered layers. Figure 8 and Figure 9 In this context, d_stack_Y represents the longitudinal center-to-center distance between layers. The total number of layers in the second cell is the maximum number of cell layers that can be accommodated within the effective cavity width under the constraint of the longitudinal center-to-center distance between layers, along the longitudinal axis in the plug-in configuration.

[0047] For example, after determining the effective cavity size and the safe center distance between cells, the total number of cells is calculated according to the insertion method. The insertion method first selects the staggered angle, specifically one of two angle schemes: 45° or 60°. After determining the staggered angle, the safe center distance between cells is multiplied by the cosine value of the staggered angle to obtain the even-numbered layer lateral offset sd_stack_X, where sd_stack_X = safe center distance between cells. The cosine of the misalignment angle, where the lateral offset of even-numbered layers represents the overall misalignment distance of even-numbered layers relative to odd-numbered layers in the length direction. Simultaneously, multiplying the cell safety center distance by the sine of this misalignment angle yields the interlayer longitudinal center distance d_stack_Y, where d_stack_Y = cell safety center distance. The sin stagger angle, where the longitudinal center distance between layers represents the vertical spacing between two adjacent cell layers in the width direction, forms the geometric basis for the layout of the battery pack.

[0048] After obtaining the longitudinal center distance between upper layers and the lateral offset of even-numbered layers, the effective cavity width is subtracted from the cell diameter. The difference is divided by the longitudinal center distance between layers, and the quotient is rounded down and then incremented by one to obtain the total number of second cell layers that can be arranged along the longitudinal axis. Subsequently, the total number of second cell layers is divided into odd-numbered layers and even-numbered layers, and the number of layers is counted separately for each.

[0049] Next, calculate the number of individual cells in odd-numbered and even-numbered layers. Odd-numbered layers have cells that are laterally aligned without offset. The number of cells in a single layer is equal to the effective cavity length minus the cell diameter, divided by the safe center distance, rounded down, and then incremented by one. That is, the number of cells in a single layer for odd-numbered layers = (effective cavity length - cell diameter) / safe center distance + 1. This calculation method is completely consistent with the calculation method for the number of cells in a straight-line configuration. Even-numbered layers have cells that are laterally offset by the same amount as the above-mentioned even-numbered layer lateral offset. The number of cells in a single layer is equal to the effective cavity length minus the cell diameter, minus the even-numbered layer lateral offset, divided by the safe center distance, rounded down, and then incremented by one. That is, the number of cells in a single layer for even-numbered layers = (effective cavity length - cell diameter - sd_stack_X) / safe center distance + 1. Because an extra offset is subtracted from the numerator, the number of cells in a single layer for even-numbered layers is usually less than or equal to the number of cells in a single layer for odd-numbered layers.

[0050] The above calculation process for the power strip is performed independently for each of the four power strip sub-schemes (45° and 60° along the length and width directions, respectively), yielding the corresponding total number of second candidate cells for each. When the power strip arrangement is along the cavity width direction, the cavity length and cavity width are interchanged, but the same calculation logic is applied: the effective cavity length and effective cavity width are interchanged, and the calculation directions for odd-numbered and even-numbered layers are interchanged, while the remaining calculation rules remain unchanged. After each of the four power strip sub-schemes is executed, the corresponding total number of second candidate cells is output, providing a complete data foundation for subsequent comparison with the straight-line scheme and global optimization.

[0051] Optionally, the total number of layers in the second battery cell includes the number of odd-numbered battery cell layers and the number of even-numbered battery cell layers. The step of determining the total number of second candidate battery cells under at least one plug-in method based on the total number of layers in the second battery cell, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers includes: For each type of power strip, the product of the number of odd-numbered cell layers and the number of cells in a single odd-numbered cell layer, and the product of the number of even-numbered cell layers and the number of cells in a single even-numbered cell layer, are added together to obtain the total number of second candidate cells for the corresponding power strip type. Among them, at least one of the insertion methods includes a method with a staggered angle of 45° and arranged along the horizontal axis, a method with a staggered angle of 45° and arranged along the vertical axis, a method with a staggered angle of 60° and arranged along the horizontal axis, and a method with a staggered angle of 60° and arranged along the vertical axis.

[0052] For example, the total number of layers in the second battery cell consists of two parts: the number of odd-numbered battery cell layers and the number of even-numbered battery cell layers. After determining the total number of layers in the second battery cell, it is divided according to the parity of the total number of layers: if the total number of layers is odd, the number of odd-numbered battery cell layers is the total number of layers plus one and divided by two, and the number of even-numbered battery cell layers is the total number of layers minus one and divided by two; if the total number of layers is even, the number of odd-numbered battery cell layers is equal to the number of even-numbered battery cell layers, both being the total number of layers divided by two. Based on this, for each type of power strip, the number of odd-numbered battery cell layers is multiplied by the number of cells in a single odd-numbered layer to obtain the total number of cells that can be accommodated in all odd-numbered layers; the number of even-numbered battery cell layers is multiplied by the number of cells in a single even-numbered layer to obtain the total number of cells that can be accommodated in all even-numbered layers; the above two products are added together to obtain the total number of second candidate battery cells under the corresponding power strip type. This calculation method fully considers the asymmetry in the number of odd and even layer cells caused by misalignment of the power strip, avoiding the counting deviation caused by simply multiplying the number of a single layer by the total number of layers, thus ensuring the accuracy of the result.

[0053] Furthermore, at least one type of power strip arrangement specifically includes four sub-schemes: a staggered arrangement at 45° along the horizontal axis, a staggered arrangement at 45° along the vertical axis, a staggered arrangement at 60° along the horizontal axis, and a staggered arrangement at 60° along the vertical axis. The staggered angle determines the specific values ​​of the longitudinal center distance between layers and the lateral offset of even-numbered layers. Arranging along the horizontal axis means that the cells are arranged one by one along the horizontal axis and stacked layer by layer along the vertical axis. Arranging along the vertical axis reverses the roles of the horizontal and vertical axes, meaning that the cells are arranged one by one along the vertical axis and stacked layer by layer along the horizontal axis. The four sub-schemes produce different layer spacing and offsets due to the different staggered angles, and the constraints on the effective cavity length and effective cavity width are reversed due to the different arrangement directions, resulting in differentiated cell accommodation results.

[0054] By calculating the total number of second candidate cells for each of the four insertion methods and comparing them with the total number of first candidate cells for the straight-line method, the arrangement method with the largest number of cells can be selected from all candidate schemes as the target arrangement method, thereby maximizing the space utilization of the battery pack while meeting the safety spacing constraints.

[0055] Furthermore, after calculating the total number of cells under the plug-in arrangement, the layout results are further refined and visualized. First, based on the layout parameters corresponding to the currently selected plug-in arrangement (including the number of cells in odd-numbered layers, the number of cells in even-numbered layers, the total number of second-layer cells, the lateral offset of even-numbered layers, and the longitudinal center distance between layers), the remaining gap dimensions of the effective cavity in the length and width directions are calculated. The remaining gap in the length direction equals the effective cavity length minus the total width occupied by the cell array in that direction, and the remaining gap in the width direction equals the effective cavity width minus the total height occupied by all cell layers. Based on this, according to the staggered arrangement rules of the plug-in arrangement, the center coordinates of all cells within the effective cavity are calculated row by row and cell by cell: odd-numbered layers are laterally aligned without offset, even-numbered layers are laterally offset by one even-numbered layer's lateral offset, and each layer of cells is equidistantly distributed in the width direction with the longitudinal center distance between layers, using half of the remaining gap in each direction as the starting coordinate to achieve centered arrangement. By traversing all layers and columns, a complete set of cell coordinates can be obtained. This coordinate set is then compiled and visualized using graphical display software. The layout result is as follows: Figure 10 As shown, Figure 10 This is a schematic diagram illustrating the cell arrangement in a plug-in layout. The even-numbered layers show a clear lateral misalignment relative to the odd-numbered layers, consistent with the geometric characteristics of a plug-in layout. Figure 10 It can be seen that when the staggered angle is 45° along the horizontal axis, it can accommodate 18 battery cells; when the staggered angle is 45° along the vertical axis, it can accommodate 16 battery cells; when the staggered angle is 60° along the horizontal axis, it can accommodate 20 battery cells; and when the staggered angle is 60° along the vertical axis, it can accommodate 20 battery cells.

[0056] Step 104: Compare the total number of the first candidate cells with the total number of at least one second candidate cells, and select the arrangement with the largest total number of cells as the target arrangement.

[0057] Step 105: Calculate the center coordinates of each cell within the effective cavity according to the target arrangement, and generate the corresponding cell coordinate set.

[0058] In some embodiments, after calculating the total number of cells for both the straight-line and plug-in configurations, the process proceeds to the scheme comparison and optimal output stage. First, the total number of the first candidate cells in the straight-line configuration and the total number of the second candidate cells for each of the four plug-in sub-schemes are combined to form a complete set containing five candidate schemes. Next, the maximum value is selected through direct numerical comparison, and the arrangement corresponding to this maximum value is marked as the target arrangement. This comparison process uses maximizing the total number of cells as the sole objective criterion, ensuring that the optimal arrangement scheme is locked from a global perspective. After determining the target arrangement, the center coordinates of all cells within the effective cavity are calculated layer by layer and cell by cell, according to the arrangement rules and parameters corresponding to this scheme (including arrangement type, staggered angle, number of cells per layer, total number of layers, lateral offset, and longitudinal center distance between layers). During coordinate calculation, the remaining gaps in the horizontal and vertical directions are first calculated based on the effective cavity size and the total size occupied by the cell array. Half of each gap is taken as the starting coordinates to achieve the centered arrangement of the cell array within the effective cavity. Then, according to the arrangement rules of odd-numbered and even-numbered layers, each layer and each column is traversed sequentially to calculate the horizontal and vertical coordinates of each cell. Finally, a complete set of cell coordinates is generated. This set of cell coordinates can be directly input into graphic display software to visualize the arrangement results, or it can be output to a computer-aided design system for engineering drawing, or distributed to automated assembly equipment as a positioning reference, achieving seamless data integration from mathematical calculation to engineering application.

[0059] For the straight-line arrangement, obtain the layer number and column number of each cell; based on the layer number and column number of each cell, multiply the initial coordinate offset by the column number minus one and the center distance in the horizontal direction to obtain the horizontal axis coordinate, and multiply the initial coordinate offset by the layer number minus one and the center distance in the vertical direction to obtain the vertical axis coordinate; for the interleaved arrangement, the horizontal axis coordinate of odd-numbered layers of cells is the initial coordinate offset plus the column number minus one multiplied by the sum of the cell diameter and the cell safety spacing; the horizontal axis coordinate of even-numbered layers of cells is the initial coordinate offset plus the even-numbered layer's horizontal offset, plus the column number minus one multiplied by the sum of the cell diameter and the cell safety spacing; the vertical axis coordinate of each layer of cells is the initial coordinate offset plus the layer number minus one multiplied by the vertical center distance between layers; summarize the center coordinates of all cells into a cell coordinate set.

[0060] Based on the cell arrangement method of the battery provided in this application, the effective cavity length and effective cavity width for cell arrangement, as well as the safe center distance and cell diameter between adjacent cell centers, are determined. Based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, the total number of first cell layers and the number of cells in a single row are calculated according to the straight arrangement method, and the total number of first candidate cells under the straight arrangement method is determined. Based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, the total number of second cell layers, the number of cells in odd-numbered single layers, and the number of cells in even-numbered single layers are calculated using trigonometric functions according to at least one insertion method. Based on the total number of second cell layers, the number of cells in odd-numbered single layers, and the number of cells in even-numbered single layers, the total number of second candidate cells under at least one insertion method is determined, covering the capacity of misaligned arrangements that are difficult to calculate manually. By comparing the total number of first candidate cells with the total number of at least one second candidate cell, the arrangement with the largest total number of cells is selected as the target arrangement to maximize the number of cells accommodated. Based on the target arrangement, the center coordinates of each cell in the effective cavity are calculated according to the arrangement rules of the target arrangement, and the corresponding set of cell coordinates is generated. The abstract arrangement is transformed into precise data, which solves the technical problem in the prior art that the arrangement of cells in the battery pack cavity relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of cells. This reduces the ineffective blank space in the battery cavity and improves the space utilization rate.

[0061] In some embodiments, after determining the total number of second candidate cells under at least one plug-in configuration based on the total number of second cell layers, the number of cells in odd-numbered single-layer configurations, and the number of cells in even-numbered single-layer configurations, the method further includes: For each type of power strip, calculate the space utilization rate corresponding to that type of power strip; If the space utilization rate is less than the preset threshold, the first equal-divided gap corresponding to the horizontal axis is calculated based on the effective cavity length, cell diameter and number of single-layer cells. The number of single-layer cells is the number of single-layer cells in odd-numbered layers and the number of single-layer cells in even-numbered layers. Add the first equal-division gap to the cell safety center distance to obtain the updated horizontal axis stacking center distance; Based on the cell safety center distance and the updated horizontal stacking center distance, the updated interlayer longitudinal center distance and the updated even-numbered layer horizontal offset are solved using the Heron formula. Based on the updated horizontal stacking center distance, the updated interlayer longitudinal center distance, and the updated even-numbered layer horizontal offset, the total number of second cell layers, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers that the effective cavity can accommodate are recalculated.

[0062] Specifically, the space utilization rate is the ratio of the sum of the projected areas of all cells within the effective cavity to the total area of ​​the effective cavity, reflecting the degree to which space is effectively utilized. The first evenly distributed gap (horizontal axis direction) refers to the gap value evenly distributed between every two adjacent cells after subtracting the total width occupied by all cells in that direction from the effective cavity length. The updated horizontal axis stacking center distance refers to the new horizontal distance between the centers of adjacent cells in the same layer after the first expansion adjustment. Heron's formula refers to the operational logic of decomposing the side lengths of a right triangle using the Pythagorean theorem. The updated inter-layer longitudinal center distance refers to the new vertical spacing of cells in adjacent layers in the longitudinal axis direction after the first expansion. The updated even-numbered layer horizontal axis offset refers to the new offset distance of the even-numbered layers relative to the odd-numbered layers in the horizontal axis direction after the first expansion.

[0063] As an example, after calculating the total number of cells in the basic power strip scheme, if the space utilization rate of the current power strip scheme still does not reach the preset threshold, an adaptive expansion and layout optimization process is initiated. The first step is the expansion of horizontal axis parameters. By actively adjusting the horizontal axis stacking center distance between adjacent cells in the same layer, a smaller vertical center distance between layers is derived using the side length relationship of right triangles. This allows more layers to be squeezed out in the effective cavity width direction, further increasing the total number of cells and laying the foundation for subsequent vertical axis parameter expansion and odd-even layer differentiation correction.

[0064] Specifically, firstly, the first evenly spaced gap in the horizontal direction is calculated based on the number of cells in a single layer under the current power strip scheme. This first evenly spaced gap reflects the total amount of remaining space in the horizontal direction. Then, this first evenly spaced gap is added to the safe center distance of the cells to obtain the updated stacking center distance in the horizontal direction, which is the new horizontal distance between the centers of adjacent cells in the same layer. This concentrates the excess space that was originally scattered in multiple gaps, increasing the lateral spacing between adjacent cells.

[0065] Based on this, using the cell safety center distance as the hypotenuse and half of the updated horizontal stacking center distance as one right-angled side, the other right-angled side is solved using the Pythagorean theorem (Heron's formula). This yields the updated inter-layer longitudinal center distance and the updated horizontal offset of even-numbered layers. This ensures that after adjusting the horizontal center distance, the vertical spacing between adjacent layers and the misalignment offset of even-numbered layers can be optimized synchronously, maintaining the rationality of the arrangement geometry. After the parameters are updated, based on the updated horizontal stacking center distance, inter-layer longitudinal center distance, and even-numbered layer horizontal offset, the total number of second cell layers that the effective cavity can accommodate, the number of cells per odd-numbered layer, and the number of cells per even-numbered layer are recalculated. (Reference) Figure 11 , Figure 11 A schematic diagram of the arrangement parameters after expanding the horizontal axis of the battery cell.

[0066] By expanding the horizontal axis parameters as described above, the remaining horizontal space that could not be utilized under a fixed-angle insert is reallocated and transformed into compression of the vertical row spacing, thereby squeezing out more layers in the width direction. If the space utilization rate after one expansion is still not up to standard, the second step of expanding the vertical axis parameters is continued, and the four-step iterative optimization process is completed in sequence until the space utilization rate meets the preset threshold or reaches the physical limit.

[0067] In some embodiments, after the step of recalculating the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells that the effective cavity can accommodate, the method further includes: Based on the effective cavity width, cell diameter, and the total number of layers in the second cell, calculate the second evenly divided gap in the longitudinal direction; Add the second evenly divided gap to the first updated longitudinal center distance between layers to obtain the second updated longitudinal center distance between layers. Determine whether the longitudinal center-to-center distance between layers after the second update is less than the safe center-to-center distance of the battery cells; If the longitudinal center distance between layers after the second update is less than the safe center distance between cells, it is determined that the vertical spacing between cells in the odd and even layers is insufficient. The horizontal offset of the even-numbered layers and the horizontal stacking center distance after the second update are calculated using the Heron formula. Based on the second updated horizontal stacking center distance, the second updated interlayer longitudinal center distance, and the second updated horizontal offset of even-numbered layers, the total number of second cell layers that the effective cavity can accommodate, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers are recalculated to obtain the second updated total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers.

[0068] Specifically, the second evenly distributed gap (vertical axis direction) is the gap value evenly distributed between every two adjacent layers after subtracting the total height occupied by all cell layers from the effective cavity width in the vertical axis direction. The interlayer longitudinal center distance after the second update refers to the new vertical spacing of adjacent cell layers in the vertical axis direction after the second step of vertical axis direction parameter expansion.

[0069] As an example, after expanding the horizontal axis parameters, the vertical axis parameters are further expanded and vertical anti-interference adjustments are made as the second step in the adaptive optimization process. Based on the compression of the vertical row spacing during horizontal axis expansion, the remaining space in the vertical axis direction is further utilized by actively increasing the vertical center distance between floors to explore the layout potential in the width direction. Simultaneously, safety judgment and active compensation mechanisms are added to ensure that the layout scheme does not violate physical interference constraints while pursuing maximum quantity.

[0070] Specifically, firstly, based on the total number of second cell layers under the current layout scheme, the second evenly distributed gap in the longitudinal direction is calculated. This second evenly distributed gap is equal to the effective cavity width minus the total height occupied by all cell layers, and then evenly distributed between every two adjacent layers. It reflects the total remaining space in the longitudinal direction of the current layout. Subsequently, this second evenly distributed gap is added to the first updated longitudinal center distance between layers to obtain the second updated longitudinal center distance between layers, which is the new vertical spacing between the centers of adjacent cell layers.

[0071] Based on this, a crucial safety judgment step is executed: determining whether the longitudinal center-to-center distance between layers after the second update is less than the safe center-to-center distance between cells. If this judgment is valid, it indicates that the cells in the odd and even layers are too close in the vertical direction, posing a risk of physical interference. In this case, an offset compensation mechanism needs to be triggered. The specific compensation method is as follows: using the safe center-to-center distance between cells as the hypotenuse and half of the longitudinal center-to-center distance between layers after the second update as one right-angle side, the other right-angle side is solved using the Pythagorean theorem (Heron's formula), thereby obtaining the horizontal offset of the even-numbered layers after the second update and the horizontal stacking center-to-center distance after the second update. The physical meaning of this offset compensation mechanism is that when the longitudinal row spacing is compressed to less than the safe center-to-center distance, by increasing the lateral misalignment of the even-numbered layers, the vertical alignment positions of the cells in the odd and even layers are staggered, thereby maintaining a smaller longitudinal row spacing while maintaining a safe distance.

[0072] After the parameters are updated, based on the updated horizontal stacking center distance, the updated interlayer longitudinal center distance, and the updated horizontal offset of even-numbered layers, the total number of second cell layers that the effective cavity can accommodate, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers are recalculated. For example... Figure 12 As shown, Figure 12 This diagram illustrates the cell layout parameters after expansion along the longitudinal axis. The even-numbered layers are further laterally offset from the odd-numbered layers after this expansion, effectively mitigating the interference risk associated with vertically aligned cells. If the updated longitudinal center-to-center distance between layers is not less than the safe center-to-center distance between cells, it indicates that the current longitudinal spacing is sufficiently safe, eliminating the need for offset compensation and allowing for direct recalculation based on the current parameters. This longitudinal expansion and safety determination mechanism enables the layout scheme to maximize the compression of longitudinal row spacing while ensuring physical safety, providing reasonable basic parameters for the odd-even layer differentiation correction in the third step.

[0073] In some embodiments, after recalculating the total number of second cell layers, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers based on the second-updated horizontal axis stacking center distance, the second-updated inter-layer longitudinal center distance, and the second-updated horizontal axis offset of even-numbered layers, and obtaining the second-updated total number of second cell layers, the second-updated number of single-layer cells in odd-numbered layers, and the second-updated number of single-layer cells in even-numbered layers, the method further includes: Determine whether the number of single-layer cells in odd-numbered layers after the second update is consistent with the number of single-layer cells in even-numbered layers after the second update; If they are inconsistent, when the number of odd-numbered single-layer cells after the second update is greater than the number of even-numbered single-layer cells after the second update, the first equal-division gap is multiplied by the product of the number of odd-numbered single-layer cells after the second update minus one, and half of the cell safety center distance is added. The resulting sum is then divided by the difference between the number of even-numbered single-layer cells after the second update minus 0.5 to obtain the updated equal-division gap in the horizontal direction. When the number of odd-numbered single-layer cells after the second update is less than the number of even-numbered single-layer cells after the second update, the first equal-division gap is multiplied by the product of the number of even-numbered single-layer cells after the second update minus 0.5, and half of the cell safety center distance is added. The resulting sum is then divided by the difference between the number of odd-numbered single-layer cells after the second update minus one to obtain the updated equal-division gap in the horizontal axis direction. The first equal-divided gap is replaced with the updated equal-divided gap along the horizontal axis. The overall arrangement is re-iterated, and the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells that the effective cavity can accommodate are recalculated. The total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells after three updates are obtained.

[0074] As an example, after completing the expansion of the vertical axis parameters and the vertical anti-interference adjustment, the third step in the adaptive optimization process is to perform a differential adjustment of the number of cells per layer. After the first two steps of horizontal and vertical expansion, due to the lateral offset of even-numbered layers, the number of cells per single layer in odd-numbered layers may differ from that in even-numbered layers. This difference can lead to some layers having underutilized corner spaces. The differential adjustment calculates the dedicated horizontal axis evenly distributed gap for different cases of odd and even layer numbers to finely adjust the overall layout, making the number of odd and even layers more consistent or reaching an optimal balance, and further squeezing out the remaining boundary space.

[0075] Specifically, first, it is determined whether the number of single-layer cells in odd-numbered layers and even-numbered layers are consistent after the second update. If they are equal, it indicates that the current layout scheme is balanced, and the third step can be skipped to the fourth step; if they are not equal, differential corrections are performed according to the two different quantity relationships. When the number of single-layer cells in odd-numbered layers is greater than the number of single-layer cells in even-numbered layers, the first correction formula is used: multiply the first equal-division gap by the product of the number of single-layer cells in odd-numbered layers minus one after the second update, add half of the cell safety center distance, and then divide by the number of cells in even-numbered layers minus 0.5 to obtain the updated equal-division gap in the horizontal axis direction. The first correction formula is: Updated equal-division gap in the horizontal axis direction = (First equal-division gap) / (First equal-division gap) / (1 / 1) = 1 / 1. (Number of cells per single layer in odd-numbered layers after the second update) + (Cell safety center distance / 2) / (Number of cells per single layer in even-numbered layers after the second update - 0.5). Using the first correction formula, the odd-numbered layers with a larger number of cells are used as the reference layers, and their total spacing in the horizontal direction is used as a constraint condition. At the same time, half of the cell safety center distance is introduced as boundary compensation, thus deriving a horizontally evenly distributed gap that allows the even-numbered layers with a smaller number of cells to accommodate more cells.

[0076] When the number of cells in an odd-numbered layer is less than the number of cells in an even-numbered layer, the second correction formula is used: multiply the first equal-division gap by the product of the number of cells in the even-numbered layer after the second update minus 0.5, add half of the cell safety center distance, and then divide by the number of cells in the odd-numbered layer after the second update minus one to obtain the updated equal-division gap in the horizontal axis direction. The second correction formula is: Updated equal-division gap in the horizontal axis direction = (Original first equal-division gap) (Number of even-numbered single-layer cells after the second update - 0.5) + (Safe center distance of cells / 2) / (Number of odd-numbered single-layer cells after the second update - 1). Using the second correction formula, taking the more numerous even-numbered layers as the base layer, and combining the number constraints of odd-numbered layers, a horizontally evenly divided gap that allows odd-numbered layers to accommodate more cells is derived.

[0077] After correcting the horizontal axis evenly distributed gap, the original first evenly distributed gap is replaced with the updated horizontal axis evenly distributed gap. The overall layout iteration is re-executed according to the first step of horizontal axis expansion layout logic. The total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers that the effective cavity can accommodate are recalculated, resulting in layout parameters updated three times. Through the above-mentioned differential correction of the number of cells in each layer, the remaining space in the horizontal axis is allocated more precisely, the difference in the number of cells between odd and even layers is effectively bridged, and the overall layout scheme is more uniform and compact in the horizontal axis direction, significantly improving space utilization. After this step, if the number of odd and even layers is still inconsistent after three updates, this step can be repeated for multiple rounds of iterative correction. If the difference in the number of cells is still not eliminated after rounds of correction but cannot be further adjusted, the fourth step of multi-layer stacking vertical interference protection adjustment is entered, ultimately ensuring maximum space utilization while completely eliminating the physical interference risks in the layout scheme.

[0078] After completing the expansion of horizontal and vertical axis parameters and the correction of odd-even layer differences, the fourth step in the adaptive optimization process is to perform adjustments to prevent vertical interference in multi-layer stacking. When the total number of cell layers in the effective cavity reaches three or more, the odd-numbered layers (first, third, fifth, etc.) will form a vertical alignment in the vertical axis direction, meaning that the horizontal projections of each odd-numbered cell layer completely overlap. If the longitudinal center distance between layers is insufficient, physical interference will occur between these vertically aligned cells, seriously affecting assembly safety and reliability. Therefore, it is necessary to further increase the longitudinal center distance between layers to completely eliminate the interference risk of vertically aligned cells.

[0079] Specifically, the first step is to determine whether the total number of layers of the second cell under the current layout scheme reaches three or more. If the total number of layers is less than three, there is no interference problem with the vertical alignment of odd-numbered layers, and this step is unnecessary; the current layout scheme can be directly output. If the total number of layers reaches three or more, the longitudinal center distance between layers is corrected according to the update formula based on the evenly distributed gap along the longitudinal axis, the number of cell layers, and the current longitudinal center distance between layers under the current operating conditions. This update formula is based on the current longitudinal center distance between layers. The product of the evenly distributed gap along the longitudinal axis multiplied by the number of cell layers minus one is added to the current longitudinal center distance between layers, and then divided by the number of cell layers minus two. The quotient is the corrected longitudinal center distance between layers. Taking into account the remaining space along the longitudinal axis and the current center distance between layers, the vertical distance between odd-numbered layers is made to meet the safety requirements through weighted amplification, while also taking into account the layout density. After the parameters are updated, the number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers are recalculated according to the expansion and arrangement logic in the vertical direction of the second step.

[0080] Given a cell diameter of 50mm, a cell gap of 1mm, an internal cavity length of 230mm, and a width of 300mm, the space utilization was low and there was a risk of vertical alignment interference before adopting this expanded arrangement method. After a four-step optimization process (i.e., first step: horizontal axis parameter expansion; second step: vertical axis parameter expansion and vertical anti-interference adjustment; third step: layer and cell quantity differentiation correction arrangement; fourth step: multi-layer stacking vertical interference protection adjustment), the arrangement effect and space utilization are compared as follows: Figure 13 As shown, Figure 13 This is a diagram comparing the layout effect and space utilization. From... Figure 13 As can be seen, there was a significant risk of interference between the vertically aligned cells in the odd-numbered layers before the expansion. After the expansion, the vertical spacing of the odd-numbered layers was reasonably increased, and the interference risk was completely eliminated. At the same time, the total number of cells increased from 24 before the expansion to 25 after the expansion, thus improving space utilization. After completing the above-mentioned multi-layer stacking vertical interference protection adjustment steps, the entire four-step optimization process is completed, and the final output is a cell arrangement scheme that meets the safety spacing requirements and maximizes space utilization.

[0081] In some embodiments, after completing the basic layout calculation, this application also provides a flexible cavity boundary adjustment mechanism to adapt to actual working conditions such as insufficient cell quantity or the need to install thermal conductive pads around the module. Specifically, when the total number of cells calculated by the straight-line method cannot meet the product design requirements, for example... Figure 5 With the shown straight-line arrangement, an effective cavity length of 200mm, a width of 300mm, a cell diameter of 21.5mm, and a cell spacing of 1mm can only accommodate 104 cells. However, the product requirement is greater than 110 cells. In this case, the size of the rectangular outline used for cell arrangement can be expanded by reducing the reserved installation space of auxiliary structural components such as the battery pack bracket and battery management system. Conversely, when thermal pads need to be placed on the outer periphery of the battery pack cell module, the cavity outline size for placing the cells needs to be reduced inward to reserve assembly space for the thermal pads. To uniformly represent the above boundary adjustment operations, this application can set a contour change size parameter boundary_gap, where the contour change size parameter takes a positive value when the cavity contour expands and a negative value when the cavity contour shrinks, such as... Figure 14 As shown, Figure 14 This is a schematic diagram showing the size comparison before and after the cavity contour adjustment.

[0082] After expanding or shrinking the cavity profile, the layout calculation logic is adaptively updated. Specifically, the calculation rule for the total number of layers in the cell width direction remains unchanged, i.e., the adjusted effective cavity width minus the cell diameter is divided by the longitudinal center distance between layers and rounded down by one; while the calculation of the number of cells in a single row requires subtracting the cell diameter from the adjusted effective cavity length and twice the boundary_gap, and then combining it with the center distance in the horizontal axis direction for calculation. Using the basic parameters of a cavity length of 200mm, a width of 300mm, a cell diameter of 21.5mm, and a cell spacing of 1mm, the cells are arranged by expanding the cavity outward by 5mm (i.e., boundary_gap is +5) and shrinking it inward by 5mm (i.e., boundary_gap is -5), respectively. The layout results under the two conditions are as follows: Figure 15 As shown. From Figure 15 As can be seen, after expanding by 5mm, the number of cells arranged increases to 117. Figure 15 The left-side layout diagram shows that it meets the design requirement of more than 110 cells; after shrinking by 5mm, the number of cells in the layout is reduced to 96. Figure 15 (See the right-hand layout diagram). While compressing the space, it provides installation leeway for the thermal pads. The aforementioned boundary adjustment mechanism enables this application to flexibly adapt to different engineering needs, achieving on-demand adjustment between maximizing the number of battery cells and reserving peripheral assembly space, further enhancing the engineering adaptability and reusability of the method.

[0083] In some embodiments, when the total number of cells calculated by the plug-in method cannot meet the product design requirements, and there is still unused space on the side of the cavity due to reserved space for auxiliary structural components, the size of the rectangular outline for cell arrangement can be expanded outward by compressing the reserved installation space of structural components such as the battery pack bracket and battery management system. Conversely, when thermal pads need to be pasted on the outer periphery of the battery pack cell module, the size of the cavity outline for placing the cells is shrunk inward to leave assembly space for the pads. This application uses the outline change size parameter boundary_gap: this parameter takes a positive value when the cavity expands outward and a negative value when it shrinks inward. Taking the specific working condition under the plug-in method as an example, the cell arrangement effect after cavity outline adjustment under the plug-in method is as follows: Figure 16 As shown. From Figure 16 As can be seen, when the staggered angle is 45°, the number of cells arranged after expansion increases to 21, and when the staggered angle is 60°, the number of cells arranged after expansion increases to 22. After the cavity contour is corrected, the calculation rule for the total number of stackable layers of cells in the longitudinal direction remains unchanged. Only the number of cells that can be accommodated in odd-numbered layers is recalculated based on the adjusted effective length of the cavity minus twice the boundary_gap and the cell diameter. This allows the plug-in arrangement scheme to be adaptively modified according to the external assembly structure of the battery pack, maximizing the loading capacity and space utilization of cylindrical cells inside the cavity.

[0084] It should be noted that the above examples are only for understanding this application and do not constitute a limitation on the cell arrangement method of the battery in this application. Any simple modifications based on this technical concept are within the protection scope of this application.

[0085] This application also provides a battery cell arrangement device, which includes: The cavity preprocessing module is used to determine the effective cavity length and effective cavity width for cell layout, as well as the safe center distance and cell diameter between adjacent cell centers; The straight-line quantization and calculation module is used to calculate the total number of layers of the first cell and the number of cells in a single row according to the straight-line method based on the effective cavity length, effective cavity width, cell diameter, and cell safety center distance, and to determine the total number of first candidate cells under the straight-line method. The plug-in quantization and calculation module is used to calculate the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells according to at least one plug-in method based on the effective cavity length, effective cavity width, cell diameter, and cell safety center distance. It also determines the total number of second candidate cells under at least one plug-in method based on the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells. The optimal selection module is used to compare the total number of first candidate cells with the total number of at least one second candidate cells, and select the arrangement with the largest total number of cells as the target arrangement. The cell coordinate generation module is used to calculate the center coordinates of each cell in the effective cavity according to the target arrangement and generate the corresponding cell coordinate set.

[0086] The battery cell arrangement device provided in this application, employing the battery cell arrangement method described in the above embodiments, can solve the technical problem in the prior art where the arrangement of cells within the battery pack cavity relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of cells. Compared with the prior art, the beneficial effects of the battery cell arrangement device provided in this application are the same as those of the battery cell arrangement method provided in the above embodiments, and other technical features in the battery cell arrangement device are the same as those disclosed in the methods of the above embodiments, and will not be repeated here.

[0087] This application provides a battery cell arrangement device, which includes: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor to enable the at least one processor to perform the battery cell arrangement method in the above embodiment 1.

[0088] The following is for reference. Figure 17The diagram illustrates a structural schematic of a battery cell arrangement device suitable for implementing embodiments of the present application. The battery cell arrangement device in the embodiments of the present application may include, but is not limited to, mobile terminals such as mobile phones, laptops, digital radio receivers, personal digital assistants (PDAs), tablet computers (PADs), portable media players (PMPs), in-vehicle terminals (e.g., in-vehicle navigation terminals), and fixed terminals such as digital TVs and desktop computers. Figure 17 The battery cell arrangement device shown is merely an example and should not impose any limitations on the functionality and scope of use of the embodiments of this application.

[0089] like Figure 17 As shown, the battery cell arrangement device may include a processing unit 1001 (e.g., a central processing unit, a graphics processing unit, etc.), which can perform various appropriate actions and processes according to a program stored in read-only memory (ROM) 1002 or a program loaded from storage device 1003 into random access memory (RAM) 1004. The random access memory 1004 also stores various programs and data required for the operation of the battery cell arrangement device. The processing unit 1001, ROM 1002, and RAM 1004 are interconnected via a bus 1005. An input / output (I / O) interface 1006 is also connected to the bus. Typically, the following systems can be connected to the input / output interface 1006: input devices 1007 including, for example, a touchscreen, touchpad, keyboard, mouse, image sensor, microphone, accelerometer, gyroscope, etc.; output devices 1008 including, for example, a liquid crystal display (LCD), speaker, vibrator, etc.; storage devices 1003 including, for example, magnetic tape, hard disk, etc.; and communication devices 1009. Communication device 1009 allows the battery cell arrangement device to communicate wirelessly or wiredly with other devices to exchange data. Although battery cell arrangement devices with various systems are shown in the figure, it should be understood that it is not required to implement or possess all the systems shown. More or fewer systems may be implemented alternatively.

[0090] Specifically, according to the embodiments disclosed in this application, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments disclosed in this application include a computer program product comprising a computer program carried on a computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device, or installed from storage device 1003, or installed from read-only memory 1002. When the computer program is executed by processing device 1001, it performs the functions defined in the methods of the embodiments disclosed in this application.

[0091] The battery cell arrangement equipment provided in this application, employing the battery cell arrangement method described in the above embodiments, solves the technical problem in the prior art where the arrangement of cells within the battery pack cavity relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of cells. Compared with the prior art, the beneficial effects of the battery cell arrangement equipment provided in this application are the same as those of the battery cell arrangement method provided in the above embodiments, and other technical features of this battery cell arrangement equipment are the same as those disclosed in the previous embodiment method, and will not be repeated here.

[0092] It should be understood that the various parts disclosed in this application can be implemented using hardware, software, firmware, or a combination thereof. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments or examples.

[0093] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0094] This application provides a computer-readable storage medium having computer-readable program instructions (i.e., a computer program) stored thereon, the computer-readable program instructions being used to execute the battery cell arrangement method in the above embodiments.

[0095] The computer-readable storage medium provided in this application may be, for example, a USB flash drive, but is not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatuses, or devices, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), optical fibers, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this embodiment, the computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, apparatus, or device. The program code contained on the computer-readable storage medium may be transmitted using any suitable medium, including but not limited to: wires, optical cables, RF (Radio Frequency), etc., or any suitable combination thereof.

[0096] The aforementioned computer-readable storage medium may be included in the cell arrangement device of the battery; or it may exist independently in the cell arrangement device not assembled into the battery.

[0097] The aforementioned computer-readable storage medium carries one or more programs that, when executed by the battery cell arrangement device, cause the battery cell arrangement device to: determine the effective cavity length and effective cavity width for cell arrangement, as well as the safe center distance between adjacent cell centers and the cell diameter; based on the effective cavity length, effective cavity width, cell diameter, and safe center distance, calculate the corresponding total number of first cell layers and the number of cells in a single row according to the straight arrangement method, and determine the total number of first candidate cells under the straight arrangement method; based on the effective cavity length, effective cavity width, and cell diameter, the battery cell safe center distance, the battery cell arrangement device to: determine the effective cavity length, effective cavity width, and safe center distance; and determine the effective cavity length, effective cavity width, and safe center distance between adjacent cells. The cell diameter and safe center distance are determined using trigonometric functions to calculate the total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers, according to at least one insertion method. The total number of second candidate cells under at least one insertion method is then determined based on the total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers. The total number of first candidate cells is compared with the total number of at least one second candidate cell, and the arrangement with the largest total number of cells is selected as the target arrangement. Based on the target arrangement, the center coordinates of each cell within the effective cavity are calculated, generating the corresponding set of cell coordinates.

[0098] Computer program products for performing the operations of this application can be written in one or more programming languages ​​or a combination thereof, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, and conventional procedural programming languages ​​such as the "C" language or similar programming languages. The program code can be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving remote computers, the remote computer can be connected to the user's computer via any type of network—including a Local Area Network (LAN) or a Wide Area Network (WAN)—or can be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0099] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation that may be implemented in systems, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0100] The modules described in the embodiments of this application can be implemented in software or hardware. The names of the modules do not necessarily limit the functionality of the unit itself.

[0101] The readable storage medium provided in this application is a computer-readable storage medium that stores computer-readable program instructions (i.e., a computer program) for executing the cell arrangement method of the battery described above. This solves the technical problem in the prior art where cell arrangement within the battery pack cavity relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of cells. Compared with the prior art, the beneficial effects of the computer-readable storage medium provided in this application are the same as those of the cell arrangement method of the battery provided in the above embodiments, and will not be repeated here.

[0102] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the steps of the battery cell arrangement method described above.

[0103] The computer program product provided in this application can solve the technical problem in the prior art where the arrangement of battery cells in the cavity of the battery pack relies on manual experience, resulting in low space utilization and difficulty in maximizing the number of cells. Compared with the prior art, the beneficial effects of the computer program product provided in this application are the same as the beneficial effects of the battery cell arrangement method provided in the above embodiments, and will not be repeated here.

[0104] The above are only some embodiments of this application and do not limit the patent scope of this application. All equivalent structural transformations made under the technical concept of this application and using the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included in the patent protection scope of this application.

Claims

1. A method for arranging battery cells, characterized in that, The battery cell arrangement method includes: Determine the effective cavity length and effective cavity width for cell layout, as well as the safe center distance between adjacent cell centers and the cell diameter; Based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, the total number of first cell layers and the number of cells in a single row are calculated according to the straight arrangement method, and the total number of first candidate cells under the straight arrangement method is determined. Based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, according to at least one insertion method, the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells are calculated using trigonometric functions. The total number of second candidate cells under at least one insertion method is determined based on the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells. Compare the total number of the first candidate cells with the total number of at least one second candidate cell, and select the arrangement with the largest total number of cells as the target arrangement. Based on the target arrangement, calculate the center coordinates of each cell within the effective cavity and generate the corresponding cell coordinate set.

2. The battery cell arrangement method as described in claim 1, characterized in that, The steps of determining the effective cavity length and effective cavity width for cell layout, as well as the safe center distance between adjacent cells, include: Obtain the original dimensional parameters of the internal cavity of the battery pack, including cavity length, cavity width, cell diameter, cell safety spacing, and reserved installation space. The cavity length and cavity width are subtracted based on the reserved installation space dimensions to obtain the effective cavity length and effective cavity width for cell layout; The cell diameter is added to the cell safety spacing to obtain the cell safety center distance between the centers of adjacent cells.

3. The method as described in claim 1, characterized in that, The step of calculating the total number of first cell layers and the number of cells in a single row based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, and determining the total number of first candidate cells under the straight-line arrangement, includes: Subtracting the cell diameter from the effective cavity width and dividing by the cell safety center distance, then rounding the resulting quotient down and adding one, yields the total number of first cell layers that can be arranged along the vertical axis. Subtracting the cell diameter from the effective cavity length and dividing by the cell safety center distance, then rounding the resulting quotient down and adding one, yields the number of cells in a single row. Multiply the total number of layers of the first cell by the number of cells in a single row to obtain the total number of first candidate cells in the straight-line arrangement.

4. The cell arrangement method of the battery as described in claim 1, characterized in that, The step of calculating the total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers based on the effective cavity length, the effective cavity width, the cell diameter, and the cell safety center distance, according to at least one insertion method, using trigonometric functions, includes: Select a staggered angle, wherein the staggered angle is 45° or 60°; Multiply the cell safety center distance by the cosine of the staggered angle to obtain the even-numbered layer lateral offset, and multiply the cell safety center distance by the sine of the staggered angle to obtain the interlayer longitudinal center distance. Subtracting the cell diameter from the effective cavity width and dividing by the longitudinal center distance between layers, then rounding the resulting quotient down and adding one, yields the total number of second cell layers that can be arranged along the longitudinal axis. The total number of layers in the second battery cell is divided into odd-numbered layers and even-numbered layers; Subtracting the cell diameter from the effective cavity length and dividing by the cell safety center distance, then rounding the resulting quotient down and adding one, yields the number of odd-numbered single-layer cells. Subtract the cell diameter and the lateral offset of the even-numbered layers from the effective cavity length, divide the resulting difference by the cell safety center distance, round down, and add one to obtain the number of cells in the even-numbered single layer.

5. The battery cell arrangement method as described in claim 4, characterized in that, The second total number of battery cell layers includes odd-numbered battery cell layers and even-numbered battery cell layers. The step of determining the total number of second candidate battery cells under at least one plug-in method based on the second total number of battery cell layers, the number of odd-numbered single-layer battery cells, and the number of even-numbered single-layer battery cells includes: For each type of power strip, the product of the number of odd-numbered battery cells and the number of single-layer cells in the odd-numbered layer is added together with the product of the number of even-numbered battery cells and the number of single-layer cells in the even-numbered layer to obtain the total number of second candidate cells for the corresponding power strip type. The at least one type of insertion method includes a method in which the staggered angle is 45° and the arrangement is along the horizontal axis, a method in which the staggered angle is 45° and the arrangement is along the vertical axis, a method in which the staggered angle is 60° and the arrangement is along the horizontal axis, and a method in which the staggered angle is 60° and the arrangement is along the vertical axis.

6. The battery cell arrangement method as described in claim 5, characterized in that, After the step of determining the total number of second candidate cells under at least one socket configuration based on the total number of layers of the second cell, the number of single-layer cells in the odd-numbered layers, and the number of single-layer cells in the even-numbered layers, the method further includes: For each type of power strip, calculate the space utilization rate corresponding to that power strip type; If the space utilization rate is less than a preset threshold, the first evenly divided gap corresponding to the horizontal axis direction is calculated based on the effective cavity length, the cell diameter and the number of single-layer cells, and the number of single-layer cells is the number of odd-numbered single-layer cells and the number of even-numbered single-layer cells. Add the first evenly divided gap to the cell safety center distance to obtain the updated horizontal axis stacking center distance; Based on the cell safety center distance and the updated horizontal stacking center distance, the updated interlayer longitudinal center distance and the updated even-numbered layer horizontal offset are solved using Heron's formula. Based on the updated horizontal stacking center distance, the updated interlayer longitudinal center distance, and the updated even-numbered layer horizontal offset, the total number of second cell layers, the number of single-layer cells in odd-numbered layers, and the number of single-layer cells in even-numbered layers that the effective cavity can accommodate are recalculated.

7. The battery cell arrangement method as described in claim 6, characterized in that, After the step of recalculating the total number of second cell layers, the number of odd-numbered single-layer cells, and the number of even-numbered single-layer cells that the effective cavity can accommodate, the method further includes: Based on the effective cavity width, the cell diameter, and the total number of layers in the second cell, calculate the second evenly divided gap corresponding to the longitudinal axis direction; Add the second evenly divided gap to the first updated longitudinal center distance between layers to obtain the second updated longitudinal center distance between layers; Determine whether the longitudinal center distance between layers after the second update is less than the safe center distance of the battery cell; If the longitudinal center distance between layers after the second update is less than the safe center distance of the cells, it is determined that the vertical spacing between cells in the odd and even layers is insufficient. The offset of the even-numbered layers in the horizontal direction and the stacking center distance in the horizontal direction after the second update are calculated using the Heron formula. Based on the second updated horizontal stacking center distance, the second updated interlayer longitudinal center distance, and the second updated even-numbered layer horizontal offset, the total number of second cell layers that the effective cavity can accommodate, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers are recalculated to obtain the second updated total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers.

8. The cell arrangement method of the battery as described in claim 7, characterized in that, After the step of recalculating the total number of second cell layers, the number of single cells in odd-numbered layers, and the number of single cells in even-numbered layers that the effective cavity can accommodate based on the second-updated horizontal stacking center distance, the second-updated inter-layer longitudinal center distance, and the second-updated horizontal offset of even-numbered layers, and obtaining the second-updated total number of second cell layers, the second-updated number of single cells in odd-numbered layers, and the second-updated number of single cells in even-numbered layers, the method further includes: Determine whether the number of odd-numbered single-layer cells after the second update is consistent with the number of even-numbered single-layer cells after the second update; If they are inconsistent, when the number of odd-numbered single-layer cells after the second update is greater than the number of even-numbered single-layer cells after the second update, the first evenly divided gap is multiplied by the product of the number of odd-numbered single-layer cells after the second update minus one, and half of the cell safety center distance is added. The resulting sum is then divided by the difference between the number of even-numbered single-layer cells after the second update minus 0.5 to obtain the updated evenly divided gap in the horizontal direction. When the number of odd-numbered single-layer cells after the second update is less than the number of even-numbered single-layer cells after the second update, the first evenly divided gap is multiplied by the product of the number of even-numbered single-layer cells after the second update minus 0.5, and half of the cell safety center distance is added. The resulting sum is then divided by the difference between the number of odd-numbered single-layer cells after the second update minus one to obtain the updated horizontal axis evenly divided gap. The first evenly divided gap is replaced with the updated horizontal axis evenly divided gap, and the overall arrangement is re-iterated. The total number of second cell layers, the number of odd-numbered single-layer cells and the number of even-numbered single-layer cells that the effective cavity can accommodate are recalculated to obtain the total number of second cell layers, the number of odd-numbered single-layer cells and the number of even-numbered single-layer cells after three updates.

9. A battery cell arrangement device, characterized in that, The device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the cell arrangement method for a battery as described in any one of claims 1 to 8.

10. A storage medium, characterized in that, The storage medium is a computer-readable storage medium, and a computer program is stored on the storage medium. When the computer program is executed by a processor, it implements the steps of the battery cell arrangement method as described in any one of claims 1 to 8.

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