Battery Cell Mounting Head for Unsorted Pack Assembly
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Solution Overview
Problem
The existing methods for assembling battery packs are cumbersome and expensive due to the need for large spaces to store and organize standardized battery cells, which requires careful sorting and alignment of cells based on polarity, leading to inefficiencies in the assembly process.
Innovation Solution
A mounting device that applies independent axial and radial forces to position battery cells accurately within a battery pack, allowing for unsorted cells to be aligned and tested on a robot arm, minimizing space requirements and enabling efficient assembly by reducing travel distances and cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If battery cells are stored in containers with predetermined polarity sorting, then assembly accuracy is improved, but space requirements and device complexity increase
Solution Approach 1:
The patent changes the parameter of force application by introducing independent axial positioning force and radial guiding force. This allows unsorted battery cells to be positioned accurately through force control rather than pre-sorting, eliminating the need for large container storage areas while maintaining assembly precision
Solution Approach 2:
The patent replaces the mechanical sorting system (containers with predetermined polarity arrangement) with a force-based positioning system. The mounting device applies controlled positioning forces to orient and place cells correctly, substituting physical pre-organization with active mechanical control during assembly
2Manufacturing precision
If battery cells are pre-sorted and organized in containers, then assembly precision is improved, but assembly time and productivity decrease
Solution Approach 1:
The patent applies preliminary action by pre-configuring the mounting device with independent axial and radial force capabilities. This preparation allows the device to directly handle unsorted cells and achieve precise positioning in one operation, eliminating the time-consuming pre-sorting step while maintaining assembly precision
Solution Approach 2:
The patent enables continuous useful action by allowing the mounting device to process unsorted cells directly without interruption for sorting. The independent force application system continuously orients and positions cells as they are fed into the device, maintaining steady assembly throughput without idle sorting operations
3Manufacturing precision
If independent axial and radial forces are applied, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent segments the positioning function into two independent force components: axial positioning force for movement along the target axis and radial guiding force for lateral positioning. This segmentation allows each force to be controlled independently through separate actuators, achieving high positioning accuracy while maintaining manageable device complexity through functional decomposition
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces the space needed for cell storage, simplifies the assembly process, and shortens the cycle time for inserting multiple battery cells into a battery pack, making the assembly of battery packs more efficient and cost-effective.
Implementation Method 1
applying an axial positioning force to the placement item (B) in order to convey the placement material to a target position (101)
Implementation Method 2
applying a radial guiding force to the placement item (B) in order to convey the placement item (B) to the target position (101)
Data Source
AI summary
The invention relates to an assembly arrangement with a mounting device, in particular for assembling a battery pack with battery cells, comprising: a robot interface for receiving the assembly device on an industrial robot, a cell interface for receiving battery cells from a conveyor, a cell aligner for aligning the battery cells in a specific position, an assembly effector for discharging the battery cells into the battery pack. Furthermore, the invention relates to a method for assembling a battery pack with battery cells.