Battery Cell Alignment Jig for Safe Sensing Block Assembly
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Solution Overview
Problem
The battery assembly process for eco-friendly vehicles is labor-intensive and prone to quality issues and safety hazards due to the manual alignment and connection of battery cells, which can lead to collisions and potential fires during the assembly of sensing blocks and leads.
Innovation Solution
A battery assembly device comprising a holder unit, an alignment jig, and a transfer unit, controlled by a controller, that automates the alignment and mounting of sensing blocks and leads, reducing manual labor and ensuring precise alignment to prevent collisions and ensure safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and connection of battery cells is used, then labor intensity is high and quality issues occur, but automation equipment complexity increases
Solution Approach 1:
The automation equipment is divided into distinct functional modules: a holder unit for gripping sensing blocks, an alignment jig for positioning leads, and a transfer unit for movement. Each module performs a specific function, allowing the system to achieve automation without requiring a single complex device. This modular segmentation resolves the contradiction by making the automation system manageable and less complex while maintaining high productivity.
Solution Approach 2:
The alignment jig acts as an intermediary device between the holder unit and the battery cell assembly. It provides a mechanical interface that facilitates precise alignment of leads during the automated assembly process, enabling quality improvement without requiring overly complex direct manipulation mechanisms. This intermediary approach simplifies the overall system architecture while achieving the desired automation and quality outcomes.
2Manufacturing precision
If manual alignment of leads is performed, then alignment precision is low leading to collisions, but automated alignment increases equipment complexity
Solution Approach 1:
The alignment jig is designed to pre-position and align leads before the sensing block is fully assembled. By performing the alignment action in advance, during a controlled stage of the assembly process, the system achieves high precision without requiring complex real-time adjustment mechanisms. This preliminary alignment prevents collisions during subsequent assembly steps while keeping the equipment design relatively simple.
Solution Approach 2:
The system replaces manual mechanical alignment operations with a controlled automated alignment mechanism. The alignment jig provides structured mechanical guidance for lead positioning, substituting imprecise manual alignment with a more precise but still mechanically-based automated system. This approach improves manufacturing precision without requiring overly complex electronic or robotic systems.
3Reliability
If sensing blocks are manually connected to battery cells, then safety hazards and potential fires occur, but automated connection requires complex control systems
Solution Approach 1:
The holder unit and transfer unit are combined into an integrated assembly mechanism that grips, positions, and connects sensing blocks in a single coordinated operation. This merging of functions into one unified device improves safety by eliminating manual handling steps where collisions and fires could occur, while avoiding the need for multiple separate complex control systems. The integrated design achieves high reliability with moderate control system complexity.
Data Source
AI summary
In accordance with an embodiment, a battery assembly device includes a holder unit configured to hold a structure and to transfer the structure to a target to be mounted, an alignment jig operatively associated with the holder unit, and configured to align the target, and a transfer unit configured to provide a moving force to the alignment jig.