Battery Module Chamber Assembly for Automated Pack Positioning
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Solution Overview
Problem
The existing battery pack assembly process is inefficient and difficult to automate due to separate assembly of the box body and battery components, leading to low yield rates and stability issues during transportation.
Innovation Solution
A battery apparatus design that integrates the assembly of the box body with battery components using intersecting extension members and separators, allowing for fast and accurate positioning of battery modules within chambers, and utilizing non-welding connections for enhanced reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the box body and battery are assembled separately in existing methods, then the assembly process allows for separate handling of components, but the assembly efficiency is low and automation is difficult to achieve
Solution Approach 1:
The patent merges the box body assembly and battery assembly into a single integrated process. The extension members serve dual functions as both box body structural components and battery positioning fixtures. Batteries are assembled directly onto the extension members during box body construction, eliminating separate assembly steps and enabling automated production.
2Reliability
If the box body and battery are assembled separately, then component handling is simplified, but transportation stability is poor and yield rate decreases
Solution Approach 1:
The extension members are pre-assembled with the box body structure before battery installation. These extension members include pre-configured positioning features such as positioning holes and connecting structures that guide battery placement. This preliminary preparation ensures stable component arrangement during transportation and assembly, reducing instability and improving yield rate.
3Strength
If traditional welding methods are used for component connection, then connection strength is achieved, but thermal deformation and insulation failures occur
Solution Approach 1:
The patent replaces welding (thermal process) with mechanical connection methods. The extension members and battery brackets use positioning holes, insertion fits, and fastening structures to achieve secure connections without heat input. This eliminates thermal deformation and insulation failures while maintaining connection strength through precise mechanical interlocking.
Data Source
AI summary
The present disclosure relates to the technical field of batteries, and discloses a battery apparatus and an assembling method thereof. The battery apparatus includes a first extension member, a second extension member, a separator, and a battery module. The first extension member and the second extension member are intersected to form a plurality of chambers, and each of the chambers is provided with one battery module. The structure of second extension member segmented by the first extension member is provided with a separator, and the separator and the first extension member are located on the same side of the second extension member; the separator is in contact with the battery module.