Battery Module Assembly with Robotic Cell Placement and Simultaneous Testing
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Solution Overview
Problem
Current battery module assembly processes lack efficiency in electrically coupling and testing battery cells while ensuring proper adhesion and sealing, leading to potential defects and reduced reliability.
Innovation Solution
A method involving robotic grasping and placement of battery cells into a shell with retainer plates, simultaneous electrical testing, adhesive application, and use of accelerators to enhance bonding, along with electrical coupling and sealing with a control circuit, optimizing the assembly process for quality and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual assembly processes are used for battery cells, then operational flexibility is maintained, but assembly efficiency and productivity are reduced
Solution Approach 1:
The system enables self-service through automated robotic manipulation where the robot performs grasping, positioning, and placement of battery cells autonomously without continuous human intervention, significantly improving assembly efficiency while maintaining operational flexibility through programmable control
Solution Approach 2:
Manual mechanical assembly operations are replaced with an automated robotic system that uses mechanical arms for grasping and positioning battery cells, transitioning from human-operated mechanical processes to automated mechanical systems to enhance productivity
2Reliability
If battery cells are assembled without simultaneous electrical testing, then assembly speed is maintained, but defect detection capability and reliability are reduced
Solution Approach 1:
The assembly process merges electrical testing operations with the mechanical placement process, where battery cells are tested electrically while being positioned and secured in the module, eliminating separate testing steps and reducing total process time while maintaining high reliability
Solution Approach 2:
The system maintains continuity of useful action by performing electrical testing continuously during the assembly process rather than as a separate discrete step, ensuring that testing occurs without interruption to the assembly flow and maximizing both efficiency and defect detection
3Strength
If adhesive is applied without accelerators, then material simplicity is maintained, but bonding strength and adhesion quality are reduced
Solution Approach 1:
The system changes the chemical parameters of the adhesive system by introducing accelerators that modify the curing characteristics and bonding properties of the adhesive, enabling faster set times and enhanced bonding strength while maintaining controlled application through automated dispensing
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 method ensures efficient and reliable assembly of battery modules by ensuring each cell is electrically tested and properly bonded, enhancing the module's physical and thermal performance while reducing defects.
Implementation Method 1
placing an adhesive on the non-electrode end of each battery cell... such that the adhesive contacts the retainer plate
Implementation Method 2
use of accelerators to enhance bonding
Data Source
AI summary
A manufacturing process flow and accompanying methods for assembling a battery module are designed to increase efficiency, reduce a footprint of the manufacturing process, reduce manufacturing time, allow for increased flexibility, and reduce costs. The process flow takes advantage of robotic functionality to combine multiple manufacturing and quality assurance operations.