Battery Module Assembly Using Cammed Conveyor Orientation

Solution Overview

Problem

Current battery module assembly processes are costly and time-consuming due to the need for high precision packaging and tooling, especially when using 'pick and place' systems, which complicate handling and alignment of individual cells and cooling fins.

Innovation Solution

A method and system that combines planar battery cells with planar cooling fins, reorients them from a horizontal to a vertical plane, and aligns them using a conveyor system with cams and lifters, allowing for compression and assembly without the need for precise carriers, enabling faster and more cost-effective assembly by eliminating the requirement for high precision tooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If 'pick and place' systems with high precision carriers are used, then alignment precision of cells and cooling fins is improved, but assembly cost and device complexity increase

Engineering Contradiction:

Improvealignment precisionVSAvoidpackaging and tooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces expensive, complex high-precision carriers with simple, low-cost disposable alignment fixtures made from conventional materials. These fixtures are used once during assembly and then discarded, eliminating the need for costly reusable precision tooling while maintaining adequate alignment for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the precision requirements by designing the alignment system to accommodate normal dimensional variations in cells and cooling fins. Instead of requiring tight tolerances, the system uses generous clearance fits and compression mechanisms that work effectively with standard manufacturing tolerances, thereby reducing the need for high-precision equipment.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If 'pick and place' systems with high precision carriers are used, then alignment precision of cells and cooling fins is improved, but assembly time and productivity decrease

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces expensive, complex high-precision carriers with simple, low-cost disposable alignment fixtures made from conventional materials. These fixtures are used once during assembly and then discarded, eliminating the need for costly reusable precision tooling while maintaining adequate alignment for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the precision requirements by designing the alignment system to accommodate normal dimensional variations in cells and cooling fins. Instead of requiring tight tolerances, the system uses generous clearance fits and compression mechanisms that work effectively with standard manufacturing tolerances, thereby reducing the need for high-precision equipment.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If discreet carriers with high precision tooling are used, then handling and alignment control is improved, but assembly cost increases

Engineering Contradiction:

Improvealignment controlVSAvoidassembly cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive, complex high-precision carriers with simple, low-cost disposable alignment fixtures made from conventional materials. These fixtures are used once during assembly and then discarded, eliminating the need for costly reusable precision tooling while maintaining adequate alignment for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the precision requirements by designing the alignment system to accommodate normal dimensional variations in cells and cooling fins. Instead of requiring tight tolerances, the system uses generous clearance fits and compression mechanisms that work effectively with standard manufacturing tolerances, thereby reducing the need for high-precision equipment.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9912004B2System for assembling a battery module

Publication Date: 2018.03.06 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery pack assembly and a method of making the same. The method includes using lifters with a cammed conveyor delivery mechanism to facilitate edgewise stacking of generally planar battery cells. The lifter spacing and cam profile are designed in such a way as to orient individual battery cell tabs and cooling fin assemblies to keep them close together but without applying significant forces to the stackable components. Combining conveyor streams allows components to be processed in parallel and sequenced correctly onto a single conveyor. Use of lifter integrated conveyor belt with cams and guides for individual battery cell orientation and sequencing promotes high speed assembly without a need to change component directions. The use of high-speed component delivery high is compatible with allowing more component placement variation, while the edgewise orientation of the components being assembled permits the use of small manufacturing footprints.