Assembling Battery Machines TRIZ Cases

See how an inflatable balloon member inside a treatment tank creates a localized dry environmen

See how segmented swoosh-shaped suction channels and extended main body length remove foreign s

Inclination measurement and roller adjustment keep pouch film aligned, preventing meandering defects and supporting continuous battery case processing.

Printed electrodes, gel electrolyte, and flexible substrates enable bendable batteries that preserve capacity and voltage in roll-to-roll production.

Rolling friction between paired winding needles reduces separator scratching and misalignment during battery electrode winding.

Brush-equipped dummy cans scrub dried salts from battery crimping surfaces, improving cleaning efficiency beyond air knives and vacuum suction.

Differential heating at the lead and case sealing regions offsets heat loss near electrode leads and improves pouch battery seal integrity.

Bonded side sections and stack compression cut separator wrinkles and dead space, raising electrode density in pouch or can cells.

A gripper-fixed, two-stage pressing process heats and compresses electrode stacks to prevent distortion and keep adhesive force uniform.

Heated press rollers push electrolyte away from the seal zone while fusing pouch layers, improving seal uniformity and preventing leakage.

Automated transfer, lift, and unwinder alignment keeps separator rolls feeding battery winding with less downtime, material loss, and dust risk.

Contoured low-COF pins and tension measurement reduce friction damage when handling thin battery separator membranes.

Current and a cross-field magnetic force counter winding needle bending under material tension, improving winding quality and speed.

Insulating layers in tab-facing electrode regions maintain thickness uniformity, reducing local resistance, swelling, and short-circuit risk.

By replacing insulating tape with a wound separator, this case keeps electrode stacks secure while reducing thickness and supporting higher energy density.

Real-time control of laser scanning against index table speed keeps electrode tab-to-can welds consistent and reduces battery joining defects.

A grooved positioning member fixes clamping pin alignment on a winding pin to prevent electrode assembly wrinkling and improve battery yield.

An inclined cutter and fixing die cut electrode tabs away from the electrode, reducing burr stress, pinholes, and cracks in secondary batteries.

Asymmetric supports guide battery cells into position despite thickness and placement errors, preventing case damage during jig insertion.

A center-hole current collector with guide channels directs electrolyte into the electrode assembly to improve filling speed and permeation.

A gravity-facing connector layout lets a removable battery mount quickly while reducing connector damage, short circuits, and misalignment.

Sector cuts and pressed uncoated tabs improve current collection, lower resistance and heat, and preserve electrolyte paths in cylindrical cells.

A protrusion-based knife cuts pouch-cell corners and side seals in one step, simplifying production and reducing scrap and insulation breakage.

Movable support assemblies align battery submodules automatically, improving module assembly efficiency while preventing insulating film damage.

A cam-adjusted probe assembly compensates for square battery swelling and thickness variation to keep tab contact uniform during charging and discharging.

Infrared sealing uses a high-conductivity, light-transmissive pressing part to heat pouch cases evenly and avoid resin or tool damage.

Optical inspection and controlled sheet transport keep electrode and separator layers aligned before lamination for higher assembly accuracy.

Automated probe card assemblies use current and historical module data to switch battery module tests quickly without manual repositioning.

Dual photographing modules inspect different battery post shapes with higher defect detection accuracy and less switching time in production.

Fixing brackets and integrated housing remove redundant battery pack parts, cutting weight and assembly steps while preserving cell support.

An integrated protective frame shields the electrode assembly during battery cell installation, improving reliability, safety, and space efficiency.

A virtual electrode roll map preserves defect coordinates and process history, helping trace battery manufacturing defects across later stages.

An intermediate transfer support decouples continuous cell-segment feeding from deposition to raise stacking speed without losing alignment.

Alternating deep and shallow wall slots let a battery cell housing vent at threshold pressure while limiting shell deformation during assembly.

A cyclic pressing track spreads loading force across electrode assemblies, reducing separator tears and improving battery case feeding yield.

A two-stage laser and compression seal bonds the lead film first, improving pouch battery sealing uniformity while shortening sealing time.

Rotating clamp and support mechanisms stabilize long battery end plates, reducing positioning errors and collisions during module assembly.

Sliding bus bar openings guide unevenly spaced battery tabs into position, easing assembly while preserving module rigidity under shock and vibration.

Edge suction plates lift before the center plate to separate curved electrode sheets cleanly and avoid adsorption failure, wrinkles, and damage.

Parallel gripper modules and a movable alignment unit speed battery cell transfer while maintaining precise positioning on the rail.

Higher central-region pressure from a variable-modulus pressing pad improves battery cell degassing while limiting electrolyte discharge and swelling.

Embossed pouch-film markers replace inconsistent piercing holes, improving vision recognition and mold-change alignment in pouch cell forming.

Dual-alumina separator coatings and controlled mandrel roughness cut winding friction, improving jelly-roll cell yield and thermal safety.

Multi-axis clamping and vertical adjustment align intermediate partition plates accurately, preventing cell scratches during battery module assembly.

Compression jigs and a pressing stage wrap and flatten insulating tape on a cylindrical electrode assembly to prevent battery shorting.

A crimped cap plate directly joins the battery can to improve hermetic sealing, add electron pathways, and avoid welding or separate anode terminals.

Automated spindle positioning uses vertical, horizontal, and eccentric adjustment to eliminate battery cell occlusion errors and cut setup time.

A segmented guide rail with a built-in pressure sensor isolates adjacent-station loads to measure electrode insertion force and prevent damage.

A screw-driven pitch adjustment mechanism changes pressing-member spacing to fit different battery cell sizes without line changeover replacement.

Flexible vacuum-sealed covers with bending-prevention inserts protect solid-state batteries from heat-transfer fluid and prevent WIP warping.

Opposing end plates keep multi-cell stacks within a set compression range despite cell thickness variation, improving fit and reducing damage.

Optical depth measurement checks molded battery pouch cavities in line, cutting inspection time and catching defective accommodation parts early.

Horizontal feed and moving winding heads keep strip tension stable for faster battery coil production with less wear and precise winding.

Segmented supports moving in inclined directions stabilize sealing-part folding and pressing in narrow battery cell gaps.

Adhesive applied on the separator during Z-fold stacking holds electrodes in place, avoiding extra alignment thickness and preserving heat transfer.

A steel tub joined to an aluminum heat exchanger plate saves battery pack space, lowers tray cost, and improves liquid cooling.

Wide tape is pressed in controlled zones across neighboring electrode patterns to raise taping throughput while limiting wrinkles and bubbles.

Pre-bent spring sheets and a stamped steel shell replace welding in AA Li-ion battery assembly, improving contact stability and production consistency.

Heat and pressure drive molten resin through current collector holes to improve center-layer welding and seal battery cell openings.

A circular three-line layout reverses first-layer cell modules to stack assemblies while cutting duplicate equipment and floor space.

A mobile stacking table and continuous separator unwinding cut electrode stacking steps while improving alignment, production rate, and cell reliability.

Module end plates and aligned stack supports keep varying cell stacks within compression range while reducing fit issues, sorting time, and cost.

A segmented protective film leaves the tab root non-adhesive, reducing pulling force, preventing cracks, and preserving current flow.

A threaded shaft and nut deform the roller pipe to tune support tension, helping thin films avoid wrinkles during production.

A supported breathable film in the battery cell cover improves gas discharge while resisting pressure-driven breakage, deformation, and leakage.

Suction-held receiving parts, vision cameras, and position sensors keep pouch cells aligned during rotation and transfer to prevent stacking damage.

Post-heating module type checks send only required batteries to rest, reducing warehouse occupancy and buffering downstream faults.

Vacuum-sealed covers and bending-prevention inserts keep solid-state batteries isolated from heat-transfer fluid while maintaining uniform WIP pressure.

Vision sensors and segmented conveyors detect and correct electrode misalignment during unit cell stacking, reducing defects and equipment bulk.

Adjustable limiting positions and detachable blocks let one loading tray fit different object models while cutting tray changeover cost.

Insulating tape and localized pressing flatten inclined tab corners to prevent electrolyte buildup and suppress side reactions in pouch cells.

A fixed stack table and reciprocating electrode transfer reduce vibration, preserve alignment, and speed battery cell Z-stacking.