Battery Module Line Layout for Multi-Model Production Resilience
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Solution Overview
Problem
In-line type battery device manufacturing systems face challenges with reduced space utilization, increased worker movements, and low production efficiency, particularly when manufacturing multiple models or dealing with failures in manufacturing devices.
Innovation Solution
A battery device manufacturing system with multiple manufacturing lines arranged in a decoupled manner, including first lines for battery cell and cell assembly, second lines for sub-battery module assembly, and third lines for battery module assembly, utilizing transfer devices like overhead conveyor belts or autonomous vehicles to optimize space and production efficiency, allowing for simultaneous production of various models and continued operation despite device failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an in-line type battery device manufacturing system is used, then the manufacturing process flows in one direction from input of basic components to discharge of final battery modules, but space utilization is reduced
Solution Approach 1:
The manufacturing system is divided into multiple independent manufacturing lines (first, second, and third lines) that can operate simultaneously. Each line handles specific manufacturing stages, allowing parallel processing of different battery device models. This segmentation enables multiple models to be manufactured concurrently without interfering with each other, thereby improving space utilization while maintaining manufacturing efficiency.
2Ease of manufacture
If an in-line type battery device manufacturing system is used, then the manufacturing process is simplified, but worker movements increase
Solution Approach 1:
By dividing the manufacturing system into separate lines for different models, workers are assigned to specific lines and can focus on repetitive tasks without needing to move between different workstations. This reduces unnecessary worker movements while maintaining process simplicity within each dedicated line.
3Device complexity
If an in-line type battery device manufacturing system is used, then the system structure is simplified, but simultaneous production of various models is difficult
Solution Approach 1:
The system is segmented into multiple independent manufacturing lines, where each line is dedicated to producing a specific battery device model. This allows simultaneous production of various models without requiring complex reconfiguration of a single in-line system. Each line maintains relative simplicity while the overall system achieves high versatility.
4Device complexity
If an in-line type battery device manufacturing system is used, then the system is easier to control, but production efficiency decreases when failures occur
Solution Approach 1:
By dividing the manufacturing system into independent lines, a failure in one line does not affect the operation of other lines. Each line can continue producing its designated model, maintaining overall production efficiency. The independent structure allows for localized problem resolution without requiring complete system shutdown.
5Productivity
If multiple second manufacturing lines are used to manufacture sub-battery modules, then production capacity increases, but space utilization is reduced in in-line configuration
Solution Approach 1:
Instead of arranging multiple second manufacturing lines in a single in-line sequence, the patent distributes them across different spatial locations and allows them to operate in parallel. The decoupled configuration enables multiple lines to coexist without requiring excessive linear space, improving space utilization while maintaining high production capacity.
Data Source
AI summary
A battery device manufacturing system is disclosed. In some embodiments, the battery device manufacturing system includes a plurality of first manufacturing lines configured to manufacture a plurality of battery cells and a cell assembly in which the plurality of battery cells are stacked, a plurality of second manufacturing lines configured to couple a busbar assembly to the cell assembly to manufacture a sub-battery module, and a plurality of third manufacturing lines configured to couple the sub-battery module to a case to manufacture a battery module, wherein one of the plurality of third manufacturing lines is configured to receive the sub-battery module from each of two second manufacturing lines among the plurality of second manufacturing lines.