Battery Cell Activation Tray Mis-Assembly and Twist Checking

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Solution Overview

Problem

Existing battery cell activation trays are prone to mal-assembly and twisting during operation, leading to collisions with battery cells and resulting in damage such as dents, scratches, and cracks, which affect the quality and performance of the batteries.

Innovation Solution

A check device and method using an external tray with a fence and an inner tray with a specific separation distance, incorporating upper and lower pillar portions of varying thicknesses to detect mal-assembly or twisting by inserting the device into the tray's separation space and determining normal or abnormal conditions based on pillar engagement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the inner tray is assembled in the activation tray, then the battery cell can be accommodated and activated, but the inner tray may be twisted during operation causing collisions with battery cells

Engineering Contradiction:

Improveactivation process reliabilityVSAvoidinner tray twisting and collision

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by checking the assembly state of the inner tray before the activation process begins. The detection device measures the position and orientation of the inner tray, and if twisting is detected, the system alerts operators to correct the issue before battery cells are placed or activated, preventing collisions and damage during operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual visual inspection of tray assembly with an automated detection device that uses sensors to measure the position and orientation of the inner tray. This mechanical system substitution enables more precise and reliable detection of twisting conditions, improving the ability to prevent collisions compared to manual checking methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual inspection of tray assembly is performed, then operators can identify mal-assembly, but the detection process is time-consuming and may miss subtle twisting

Engineering Contradiction:

Improvetray assembly detection accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual visual inspection with an automated detection device that uses sensors to measure the position and orientation of the inner tray. This substitution enables rapid, precise measurement of tray assembly state without the time consumption and human error associated with manual inspection, while maintaining high detection accuracy for even subtle twisting

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection device creates a digital representation or measurement model of the inner tray's position and orientation, allowing for precise quantitative analysis of assembly state. This copying approach enables automated comparison against tolerance thresholds, improving both detection accuracy and speed compared to subjective manual assessment

Inventive Principle:

Principle #26Copying

Data Source

PatentEP4203151B1Apparatus and method for checking for mis-assembly of battery cell activation tray or twisting thereof during operation

Publication Date: 2026.02.18 LG ENERGY SOLUTION LTD

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AI summary

The present invention provides a check device for checking the mal-assembly or the twisting during operation of the battery cell activation tray and a check method for checking the occurrence of the mal-assembly or the twisting during operation of the battery cell activation tray using the check device described above.