A stacking positioning and alignment tooling for easy use of energy storage battery modules

Abstract

A stacking positioning and alignment fixture for energy storage battery modules has achieved several breakthroughs in the field of energy storage battery manufacturing: Through a unique elastic constraint frame and self-locking cam mechanism, it achieves real-time mechanical expansion stress compensation, solving the connection failure problem caused by cell cyclic expansion. Furthermore, the hierarchical positioning frame with rigid-flexible coupling topology optimization strictly controls cell misalignment, reducing module internal resistance dispersion and providing millimeter-level stacking accuracy for GWh-level energy storage modules. Simultaneously, the hollow frame design increases the contact area of ​​the liquid cooling plate, synergistically optimizing thermal resistance reduction and heat dissipation uniformity. In addition, the fixture has cross-generational production line compatibility; a single system can adapt to various cell specifications, reducing maintenance costs and promoting the leap towards flexibility and standardization in energy storage manufacturing.

Description

Technical Field

[0001] This article belongs to the field of new energy battery manufacturing technology, specifically involving a stacking positioning and alignment tooling for energy storage battery modules. Background Technology

[0002] With the accelerated global energy transition, large-scale energy storage power stations, as key infrastructure for balancing grid fluctuations and enhancing the absorption capacity of renewable energy, are experiencing explosive growth. Energy storage battery modules are the core units constituting these giant energy storage systems. Their large-scale, high-efficiency, and low-cost manufacturing capabilities directly determine the economics and competitiveness of energy storage power stations. In the module manufacturing process, the precise stacking and positioning alignment of battery cells is the primary factor affecting module performance and reliability. High-precision alignment is the foundation for ensuring low internal resistance and uniform current distribution within the module, which is directly related to energy conversion efficiency, thermal management temperature uniformity, and long-term cycle life. Stacking and positioning alignment tooling serves as the core carrier for achieving this high-precision manufacturing. Its performance not only affects the quality of individual modules but is also a key bottleneck for the efficient, consistent, and safe mass production of large-scale energy storage battery modules. Especially in the energy storage field, which pursues the ultimate manufacturing cost, the development of efficient, precise, reliable, and easy-to-operate stacking and positioning tooling has extremely important industrial significance.

[0003] However, current mainstream battery module stacking and positioning tooling technologies still have some shortcomings in meeting the stringent requirements of large-scale energy storage manufacturing, such as:

[0004] Multi-cell collaborative positioning and clamping failure: Traditional tooling makes it difficult to apply uniform and controllable clamping force to multiple cells during stacking, which can easily lead to misalignment between cells. This not only causes uneven current distribution during charging and discharging and accelerates capacity decay, but is also the main cause of excessive temperature difference inside the module, seriously threatening the long-term operational safety and lifespan of the energy storage system.

[0005] Lack of dynamic adaptability during service life: Energy storage batteries will generate significant axial expansion during frequent charge and discharge cycles. Existing tooling is mostly a static rigid structure, lacking an effective real-time pressure compensation mechanism. This causes the initial clamping force to gradually decay during the battery's life cycle, which may lead to safety hazards such as loose connecting pieces, poor welding, or even structural cracking. It cannot meet the high reliability service requirements of energy storage systems for several years or even more than ten years.

[0006] Insufficient efficiency and flexibility: Traditional tooling is cumbersome to operate and has low assembly efficiency, making it difficult to meet the needs of rapid production of large-scale energy storage modules. At the same time, its structure is often fixed and simple, making it difficult to flexibly adapt to different sizes and types of energy storage cells, which increases the cost of production line switching.

[0007] In response to the aforementioned issues, the future development of positioning and alignment tooling for energy storage battery module stacking should focus on the following aspects:

[0008] Develop a positioning and clamping mechanism that can proactively adapt to individual differences in battery cells and dynamic changes in the stacking process, ensuring the positional accuracy and uniform force distribution of each battery cell under large-scale stacking, and fundamentally solving the problems of misalignment and thermal imbalance.

[0009] The tooling structure needs to be optimized in topology to maximize the open heat dissipation channels and achieve seamless integration with the battery thermal management system, while ensuring sufficient rigidity and positioning accuracy.

[0010] Integrating a simple and reliable displacement or pressure sensing mechanism, it monitors the stacking status and clamping force changes during service in real time, providing data support for process optimization and predictive maintenance, improving the reliability of tooling for long-term use, and meeting the full life cycle management needs of energy storage systems.

[0011] The design incorporates a highly modular and standardized tooling system, enabling efficient and low-cost switching between different specifications of energy storage cell modules through rapid replacement of key positioning components. This enhances production line flexibility and adapts to the trend of multi-category development in the energy storage market. Utility Model Content

[0012] To address the three core problems in the manufacturing process of large-scale energy storage battery modules mentioned in the background technology—multi-cell collaborative positioning failure, lack of dynamic adaptability during service life, and low operating efficiency—this paper proposes a modular dynamic compensation stacking positioning and alignment fixture. Through an original adjustable support mechanism and hierarchical constraint framework, it ensures millimeter-level positioning accuracy while actively adapting to the cyclic expansion characteristics of the cells and supporting rapid model changeover production, fundamentally solving the reliability bottleneck of energy storage modules during long-term service.

[0013] A stacking positioning and alignment fixture for easy use of energy storage battery modules. The battery positioning frame adopts a hollow guide rail structure with symmetrical distribution on both sides. The guide grooves and reinforcing ribs on its surface form a bidirectional sliding pair.

[0014] in:

[0015] The internal reinforcement structure forms a detachable mechanical interlock with the side of the battery electrode assembly through the dovetail plug assembly, and a compensation gap is reserved in the direction of cell expansion to realize the lateral position constraint and directional release of expansion stress.

[0016] The external reinforcement structure is rigidly connected to the base platform by high-strength bolts to form a torsional support skeleton. Its cross-section adopts an I-shaped beam with topological optimization design, which still maintains sufficient bending stiffness under weight reduction conditions.

[0017] In summary, this dual-stage reinforcement system achieves differentiated control from rigid positioning to elastic compensation in the X, Y, and Z directions, overcoming the problem of cell expansion force accumulation caused by the rigid constraints of traditional tooling.

[0018] The support bracket innovatively integrates a cam and a threaded fine-tuning mechanism:

[0019] The eccentric cam profile curve is optimized through dynamic simulation, and its lift angle is designed to be 15°-25°. Within a 60° rotation stroke, it drives the stop block to produce a linear displacement of 0-8mm.

[0020] The threaded fine-tuning component is embedded inside the stop block, and the clamping force can be finely adjusted by ±0.05mm through the fine thread screw. Combined with the self-locking characteristic of the cam, it ensures that the clamping force attenuation rate is <5% during the service life.

[0021] This device breaks through the limitations of complex piping in traditional press fitting, achieving precise millinewton-level pressure control with a purely mechanical structure.

[0022] The bottom end of the hoop is connected to the base via a standardized quick-change slot:

[0023] The slot is fitted with a hardened steel bushing, which engages with the tapered locating pin at the bottom of the hoop, and this structure can be locked in place with only bolts.

[0024] In summary, this structure enables plug-and-play positioning frames for batteries of different sizes, improving production line changeover efficiency.

[0025] Beneficial effects

[0026] This paper achieves several breakthroughs in the field of energy storage battery manufacturing: Through an original elastic constraint frame and self-locking cam mechanism, real-time mechanical expansion stress compensation is achieved, solving the connection failure problem caused by cell cyclic expansion. Furthermore, a hierarchical positioning frame with rigid-flexible coupling topology optimization is adopted to strictly control the misalignment between cells, reduce the dispersion of module internal resistance, and provide millimeter-level stacking accuracy for GWh-level energy storage modules. At the same time, the hollow design of the frame increases the contact area of ​​the liquid cooling plate, synergistically optimizing thermal resistance reduction and heat dissipation uniformity. In addition, the tooling has cross-generational production line compatibility, and a single system can be adapted to multiple cell specifications, reducing operation and maintenance costs and promoting the leap of energy storage manufacturing towards flexibility and standardization. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of a stacking, positioning, and alignment fixture for easy use in energy storage battery modules;

[0028] Figure 2 This is a schematic diagram of the base frame structure of a stacking positioning and alignment tooling for energy storage battery modules.

[0029] Figure 3 This is a schematic diagram of a battery positioning frame structure for a stacking positioning and alignment tooling that facilitates the use of energy storage battery modules.

[0030] Figure 4This is a schematic diagram of a battery electrode assembly that facilitates stacking, positioning, and alignment of energy storage battery modules.

[0031] Figure 5 This is a top view of a stacking, positioning, and alignment fixture for energy storage battery modules.

[0032] In the diagram, 1 is the base module, 101 is the base platform, 102 is the positioning baffle, 103 is the hoop, 2 is the positioning frame module, 201 is the battery positioning frame, 202 is the reinforcing rib, 203 is the support bracket, and 3 is the battery terminal group. Detailed Implementation

[0033] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.

[0034] Base module 1, base platform 101, positioning baffle 102, hoop 103, positioning frame module 2, battery positioning frame 201, reinforcing rib 202, support bracket 203, battery electrode group 3.

[0035] like Figure 1 , 2 As shown in Figures 3, 4, and 5, the following is a detailed description of a stacking positioning and alignment fixture for easy use with energy storage battery modules:

[0036] Base module 1:

[0037] Base 101: Rectangular alloy base plate with vertical protective plates on all four sides, and anodized surface.

[0038] Positioning baffle 102: It is vertically fixed to one end of the base platform 101 along its length. It is made of steel plate and is connected to the base platform 101 by bolts.

[0039] Hoop 103: A rectangular frame with a tapered positioning pin welded to the bottom and the top welded to the upper edge of the battery positioning frame 201.

[0040] Positioning Frame Module 2:

[0041] Battery positioning frame 201: A double-sided symmetrical alloy hollow frame with multiple linear guide rails on each side.

[0042] Reinforcing rib 202:

[0043] External reinforcement structure: topology-optimized I-beam, made of alloy, with its lower end connected to the base platform 101 by high-strength bolts.

[0044] Internal reinforcement structure: It can slide into the guide rail and has a dovetail plug at the end to connect with the dovetail groove on the side of the battery terminal group 3. The insertion surface has a radial expansion gap of 0.5mm, and the axial part is provided with an initial preload through a disc spring assembly to achieve elastic constraint and release stress.

[0045] Support bracket 203:

[0046] Abutting block: One end contacts the end face of the battery cell, and the other end has an arc groove to match the profile of the cam.

[0047] Cam: Eccentric circular profile, made of bearing steel, with a lift angle designed to be smaller than the friction angle to ensure self-locking in the clamping position.

[0048] Battery electrode group 3:

[0049] The battery cell is square and has a dovetail groove on the side.

[0050] Implementation Example

[0051] Taking a 280Ah square aluminum-cased energy storage cell module stack as an example, the performance of the tooling is verified:

[0052] Step 1: Cell stacking and positioning

[0053] Place the battery electrode assembly 3 into the battery positioning frame 201, and align the dovetail groove with the inner reinforcing rib 202 plug.

[0054] Slide the inner reinforcing rib 202 along the guide rail to the side of the cell, and preload the disc spring to 200N;

[0055] Laser scanning of the cell side: maximum misalignment 0.25mm.

[0056] Step 2: End clamping and pressure calibration

[0057] The rotating cam rotates 60°, driving the abutment block to contact the end of the battery cell, applying an initial pressure of 2000N;

[0058] Adjust the fine-tuning screw to ensure that the pressure difference between the cells in the module is ≤150N;

[0059] Cam self-locking verification: Apply load fluctuation ±10%, pressure decay ≤1%.

[0060] Step 3: Expansion Stress Compensation Test

[0061] Simulated charge-discharge cycle: The hydraulic cylinder pushes the cell end plate to expand axially by 1.2mm;

[0062] Step 4: Verify heat dissipation performance

[0063] Infrared thermal imaging measurement: Under tooling clamping, the contact area between the liquid cooling plate and the cell surface accounts for 92%;

[0064] Thermal resistance test: Interfacial thermal resistance 0.025 K·m 2 / W.

[0065] Step 5: Production Line Changeover Operation

[0066] Remove the bolts from hoop 103;

[0067] Replace the positioning frame with one that is compatible with 320Ah battery cells and lengthen the inner reinforcing rib 202;

[0068] Insert the tapered pin into the new slot and lock the bolt in place.

[0069] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A stacking positioning and alignment fixture for easy use of energy storage battery modules, characterized in that, include: Base module, positioning frame module, and battery electrode assembly; The base module includes: a base platform, a positioning baffle, and a hoop; The positioning frame module is located at the center of the base module and includes: a battery positioning frame, reinforcing ribs, and a support bracket; The battery electrode assembly is installed within the positioning frame module; in: The battery positioning frame is a double-sided symmetrical hollow structure with multiple guide rails on both sides; The reinforcing ribs include: an inner reinforcing structure slidably disposed on the guide rail, and an outer reinforcing structure connected to the base platform; The internal reinforcing structure forms a detachable mechanical interlock with the side of the battery electrode assembly, and a radial expansion gap is reserved. The aforementioned support bracket includes: abutment block and cam; The cam contacts the stop block through an eccentric profile, drives the stop block to move linearly and applies a clamping force to the end of the battery electrode assembly, and the profile design of the cam has a self-locking characteristic. The bottom end of the hoop is connected to the base platform via a quick-change connection structure.

2. The stack positioning and alignment fixture of claim 1, wherein, The mechanical interlock between the inner reinforcing structure and the battery electrode assembly is a dovetail connector assembly, including a dovetail plug at the end of the inner reinforcing structure and a matching dovetail groove on the side of the battery electrode assembly.

3. The stack positioning and alignment fixture of claim 1, wherein, The radial expansion gap reserved in the dovetail connector assembly is 0.3mm–0.8mm.

4. The stack positioning and alignment fixture of claim 1, wherein, The inner reinforcing structure and the guide rail are provided with a disc spring preload assembly, which provides initial preload and axial elastic constraint.

5. The stack positioning and alignment fixture of claim 1, wherein, The cross section of the external reinforcement structure is an I-shaped beam with topology optimization design, and it is connected to the base platform by high-strength bolts.

6. The stack positioning and alignment fixture of claim 1, wherein, The cam has a lift angle of 15°–25° and drives the stop block to produce a linear displacement of 0–8 mm within a 60° rotation stroke.

7. The stack positioning and alignment fixture of claim 1, wherein: The abutment block has an embedded threaded fine-tuning mechanism, which uses a fine-toothed screw to fine-tune the clamping force with an adjustment accuracy of ±0.05mm.

8. The stack positioning and alignment fixture of claim 1, wherein, The quick-connect structure includes: A slot is provided on the base platform; A locating pin located at the bottom of the hoop; The positioning pin engages with the slot and is secured with bolts.

9. The stacking positioning and alignment fixture according to claim 1, characterized in that, The locating pin is a tapered locating pin, with a hardened steel bushing embedded in the slot, forming an interference fit between the two.

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