Battery Assembly Clamping Feedback for Accurate Welding Alignment
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Solution Overview
Problem
Inaccurate clamping position and force during the assembly of battery housings and end covers lead to welding failures and scrapping of batteries due to misalignment and uneven clamping forces.
Innovation Solution
A battery assembly method that includes feedback mechanisms to ensure precise alignment and clamping by comparing actual displacement and force values with preset thresholds, allowing for real-time adjustments and corrections to achieve accurate positioning and clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional clamping and pressing operations are performed without real-time monitoring, then the manufacturing process is simple and fast, but the clamping position accuracy and clamping force consistency deteriorate, leading to welding failures
Solution Approach 1:
The patent implements real-time monitoring of clamping position and force through sensors, with feedback signals sent to a control unit. The system compares actual values with preset thresholds and automatically adjusts clamping operations to maintain precision within acceptable ranges, resolving the contradiction between simplicity and precision.
Solution Approach 2:
The patent replaces manual or open-loop mechanical clamping operations with a closed-loop automated system that uses electronic sensors, control units, and automated adjustment mechanisms. This substitution enables precise control of clamping position and force while maintaining operational efficiency.
2Reliability
If clamping force is increased to ensure welding quality, then welding reliability improves, but the risk of deforming the battery assembly increases
Solution Approach 1:
The patent dynamically adjusts clamping force parameters based on real-time monitoring. The control unit receives feedback on actual clamping force and position, comparing them against preset thresholds, and automatically modifies the clamping force to maintain welding reliability while preventing deformation of the battery assembly.
Solution Approach 2:
The patent transitions from static, fixed clamping force to dynamic, adaptive clamping force control. The system continuously monitors clamping conditions and adjusts forces in real-time, enabling the clamping system to adapt to variations in battery assembly geometry and welding requirements without causing deformation.
3Manufacturing precision
If multiple clamping points are used to improve alignment, then positioning accuracy improves, but the device complexity and operation time increase
Solution Approach 1:
The patent combines multiple clamping functions into an integrated automated system. Multiple clamping points are controlled by a unified control unit that coordinates their actions based on real-time feedback, achieving precise alignment across all points simultaneously without requiring sequential manual adjustment, thus maintaining high assembly speed.
Solution Approach 2:
The control unit serves multiple functions: monitoring position, measuring force, comparing against thresholds, and controlling multiple clamping actuators. This multi-functionality enables the system to manage multiple clamping points efficiently, achieving high alignment accuracy without proportionally increasing operational complexity or time.
Data Source
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AI summary
Provided is a battery assembly assembling method, including: acquiring a pressing displacement amount of a pressing device; controlling a clamping device to clamp a battery assembly if an absolute value of a difference between the pressing displacement amount and a standard pressing displacement amount is less than or equal to a preset threshold; acquiring a first actual displacement amount and a first clamping force of the clamping device; and completing assembling if an absolute value of a difference between the first actual displacement amount and a first standard displacement amount is less than or equal to a first displacement threshold, and an absolute value of a difference between the first clamping force and a first standard clamping force is less than or equal to a first clamping force threshold. Provided is a battery assembly clamp, including: a control unit, and a pressing device, a clamping device, a first feedback unit and a second feedback unit respectively electrically connected to the control unit, where the first feedback unit is configured to acquire a pressing displacement amount of the pressing device; and the second feedback unit is configured to acquire a first actual displacement amount and a first clamping force of the clamping device. Provided is a welding device, including the above clamp. The problem that a clamping position and a clamping force of the battery assembly cannot be determined is solved.