Battery Cell Carrier Assembly for Precise Pack Placement
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Solution Overview
Problem
The production of high-voltage energy storage units for motor vehicles is complex due to the large number of energy storage cells, requiring a method that is both flexible and simple to manage and arrange effectively.
Innovation Solution
A method involving the use of carriers to position and arrange energy storage cells in the z-direction on a target structure, allowing for flexible placement, orientation, and treatment, including cleaning, monitoring, and interconnection, using carriers with movable baseplates and assistive elements to facilitate efficient assembly and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If energy storage cells are arranged manually one by one in the target structure, then positioning precision can be achieved, but production time and complexity increase significantly
Solution Approach 1:
The method segments the assembly process by first arranging cells on a carrier in a controlled environment, then transferring the entire carrier assembly to the target structure. This divides the complex task of individual cell placement into two simpler sub-tasks: carrier loading and carrier installation.
Solution Approach 2:
Energy storage cells are pre-arranged on the carrier before the carrier is positioned in the target structure. This preliminary arrangement allows for precise positioning to be achieved in advance, during a controlled preparation phase, rather than during the final assembly operation.
2Ease of manufacture
If the carrier is designed with fixed structure, then manufacturing simplicity is maintained, but flexibility in cell arrangement and accessibility is reduced
Solution Approach 1:
The carrier incorporates movable baseplates that can shift position, allowing the carrier structure to adapt dynamically to different cell arrangement requirements. This dynamic element enables flexible cell positioning while maintaining the overall simplicity of the carrier's fixed framework.
3Manufacturing precision
If energy storage cells are arranged after carrier positioning, then final position accuracy is improved, but assembly complexity and time increase
Solution Approach 1:
The method performs the cell arrangement action in advance on the carrier, before the carrier is installed in the target structure. This preliminary arrangement ensures final position accuracy is achieved during the preparation phase, not during final assembly.
Solution Approach 2:
The method merges the cell arrangement operation with the carrier preparation process. By combining these two actions into a single preparatory phase, the method reduces assembly complexity while maintaining position accuracy.
4Adaptability or versatility
If multiple carriers are used for cell arrangement, then arrangement flexibility is improved, but device complexity and handling difficulty increase
Solution Approach 1:
The carrier is designed as a universal platform that can accommodate different cell types and arrangements through its movable baseplates and standardized structure. This single multi-functional carrier design eliminates the need for multiple specialized carriers, reducing system complexity while maintaining flexibility.
Data Source
AI summary
A method for producing an energy store for a motor vehicle, including providing a plurality of energy storage cells, arranging the energy storage cells on or at a carrier, positioning the carrier above a target structure, the target structure extending in an xy-plane, and arranging the energy storage cells in the z-direction on or in the target structure, in particular by opening or releasing the carrier at least in some regions or sections.