Battery Module Frame Weld Durability Under Simulated Cell Swelling
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Solution Overview
Problem
Conventional methods for evaluating the durability of battery module frames, particularly the welded portions, are time-consuming and inefficient, especially in simulating the swelling phenomenon of battery cells during charge and discharge cycles.
Innovation Solution
An apparatus and method that applies pressure to the battery module frame using a pressing unit, including a pressing member and cylinder, to simulate the swelling phenomenon, while using displacement and pressure sensors to measure the durability of the welded portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated charge and discharge testing is used to evaluate battery module frame durability, then the swelling force of battery cells can be assessed, but the evaluation process takes a long time
Solution Approach 1:
The patent applies preliminary action by pre-installing the pressing unit with pressing members at positions corresponding to battery cell locations within the battery module frame. This allows the swelling force to be directly applied during the evaluation process, eliminating the need for time-consuming repeated charge and discharge cycles to generate swelling effects. The evaluation can proceed immediately with accurate durability assessment.
Solution Approach 2:
The patent replaces the electrochemical swelling process (charge and discharge cycles) with a direct mechanical pressing system. The pressing unit applies simulated swelling force mechanically to the battery module frame, substituting the lengthy electrochemical process with an immediate mechanical equivalent, thereby dramatically reducing evaluation time while maintaining reliability.
2Stability of the object's composition
If conventional evaluation methods are used for battery module frame, then structural stability can be assessed, but it is difficult to secure fatigue property data for welded portions
Solution Approach 1:
The patent applies local quality by positioning specific pressing members at locations corresponding to welded portions of the battery module frame. This localized pressing approach concentrates the applied force on critical welded areas, enabling precise measurement of fatigue properties at these specific locations while still maintaining overall structural stability assessment.
Solution Approach 2:
The pressing unit acts as an intermediary that transmits controlled force specifically to welded portions of the battery module frame. This intermediary mechanism enables direct measurement of fatigue properties at welded joints by mediating between the evaluation system and the target structure, providing accurate fatigue data that was previously difficult to obtain.
3Manufacturing precision
If initial outer frame structure analysis is performed repeatedly, then design improvements can be made, but the review process takes a long time
Solution Approach 1:
The patent enables self-service evaluation where the battery module frame undergoes automated durability testing through the pressing unit. The system automatically applies simulated swelling forces, measures responses through sensors, and generates evaluation data without requiring repeated manual analysis cycles, thereby improving design review efficiency while maintaining manufacturing precision.
Solution Approach 2:
The pressing unit performs preliminary durability evaluation before final design approval. By conducting this simulation in advance, designers can identify potential issues early in the design process, reducing the need for repeated analysis cycles and accelerating the overall design review process while maintaining high design quality.
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
Enables rapid evaluation of the durability of the welded portions by replicating the swelling effect, providing accurate data on fatigue and lifespan, thus enhancing the design efficiency of battery module frames.
Implementation Method 1
a pressing cylinder which is installed on an upper portion of the pressing member and presses the pressing member in a downward direction to allow pressure to be applied to the bottom side of the battery module frame
Implementation Method 2
a displacement sensor which measures a displacement degree of the bottom side of the battery module frame
Data Source
AI summary
The present disclosure relates to an apparatus and method for evaluating durability of a battery module frame for a vehicle. According to the present disclosure, it is possible to easily evaluate the durability or a similar quality of the welded portion of the battery module frame by providing constraints similar to a situation in which a swelling phenomenon occurs in a battery cell in the battery module frame.