Adjustable Dummy Assembly for Battery Tab-Busbar Weld Inspection
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Solution Overview
Problem
Existing methods for inspecting weld strength between lead tabs and busbars in battery cells generate significant waste and lack flexibility to adapt to varying product standards.
Innovation Solution
A dummy assembly with adjustable distance and fixation mechanisms for simulating weld conditions, allowing inspection of weld strength without discarding components and accommodating diverse product standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dummy module is manufactured for each specific standard, then weld strength inspection accuracy for that standard is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The dummy assembly is designed with adjustable components that allow a single device to accommodate multiple battery cell standards and specifications. The distance adjustment part enables the dummy assembly to be configured for different inspection requirements, eliminating the need to manufacture separate dummy modules for each standard while maintaining inspection accuracy across various product types.
2Reliability
If a dummy module is manufactured for each specific standard, then compliance with specific product standards is improved, but adaptability to varying standards deteriorates
Solution Approach 1:
The dummy assembly incorporates adjustable components including a distance adjustment part that can modify the configuration to match different battery cell standards. This dynamic adjustability allows the same dummy assembly to comply with various product standards without requiring multiple fixed designs, thereby maintaining both reliability and adaptability.
3Measurement precision
If actual battery cells are used for weld strength inspection, then inspection accuracy is improved, but waste generation increases
Solution Approach 1:
Instead of using actual battery cells for inspection, the patent employs a dummy assembly that replicates the essential structural and mechanical characteristics of real battery cells. This copy provides sufficient accuracy for weld strength inspection while eliminating the need to discard functional battery cells, thereby reducing waste without compromising measurement precision.
Data Source
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AI summary
The present application can provide a dummy assembly comprising: a first body part on which a first busbar assembly, including a first lead tab dummy and a first busbar of which at least a portion is welded to the first lead tab dummy, is mounted; a second body part on which a second busbar assembly, including a second lead tab dummy and a second busbar of which at least a portion is welded to the second lead tab dummy, is mounted; and a distance adjustment part for adjusting the distance between the first body part and the second body part.