Battery Cross Member Welding Core Insertion
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Solution Overview
Problem
The thermal deformation of cross members with closed square cross-sectional shapes during laser welding leads to gaps and reduced welding quality when assembling parts like case support brackets and battery modules in electric vehicle battery cases.
Innovation Solution
A system that minimizes thermal deformation by using a core with inclined slip surfaces and magnet members, inserted into the closed section of the cross member, which allows for precise alignment and clamping, and a welding jig with a core supply mechanism to maintain the core's position during laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to bond parts to the cross member, then welding efficiency and automation are improved, but thermal deformation occurs causing gaps and reduced welding quality
Solution Approach 1:
A core is introduced as an intermediary component inserted into the closed section of the cross member. This core acts as a mediator that absorbs or redistributes thermal energy during laser welding, preventing direct thermal deformation of the cross member structure while enabling continuous laser welding automation
Solution Approach 2:
The core is pre-installed into the closed section of the cross member before the laser welding process begins. This preliminary action prepares the structure to withstand thermal effects during welding, preventing deformation before it occurs rather than correcting it afterward
2Strength
If the cross member has a closed square cross-sectional shape, then structural strength and rigidity are improved, but thermal deformation during welding increases due to heat accumulation
Solution Approach 1:
The core is nested within the closed square cross-sectional structure of the cross member. This nested configuration allows the core to internally manage thermal effects while preserving the external closed-section geometry that provides structural strength and rigidity
Solution Approach 2:
The core modifies the thermal properties locally within the closed section without changing the overall cross member geometry. This localized intervention maintains the structural integrity provided by the closed square shape while addressing thermal deformation in the specific region where the core is inserted
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 system enhances the laser welding quality by preventing gaps between the cross member and assembled parts, ensuring a stronger and more reliable bond.
Implementation Method 1
a plurality of first magnet members (30) installed on one surface of the first core block (10), and a plurality of second magnet members (40) installed on one surface of the second core block (20)
Data Source
AI summary
Disclosed is a system of assembling a cross member for a battery case. The system of assembling a cross member for a battery case laser-welds a part to be assembled to the cross member with a closed section. The system of assembling a cross member may include: a welding jig configured to clamp the cross member; a core configured to be inserted into the closed section of the cross member clamped to the welding jig; and a core supply jig configured to insert the core into the closed section of the cross member.