Circular Battery Module Assembly Layout for Stacked Cell Reversal
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Solution Overview
Problem
Conventional assembly line facilities for battery modules require redundant investment and inefficient space usage when manufacturing stacked battery modules, necessitating two facilities with the same concept due to unidirectional logistics flow.
Innovation Solution
An assembly line system comprising three facility lines arranged in a circulation structure of a '□' shape, including a first line for cell housing, a second line for electric connections and voltage sensing, and a third line for cell connection and inspection, with reversible assembly processes to facilitate efficient stacking of cell module assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional unidirectional logistics flow is used for battery module assembly, then existing assembly line facilities can be applied, but redundant facility investment is required and space usage becomes inefficient
Solution Approach 1:
The patent merges multiple facility lines into a single integrated circular logistics flow system. The first, second, and third facility lines are connected in sequence to form a closed loop, allowing multiple functions (cell housing assembly, electric connection assembly, and series connection/inspection) to be performed in one continuous circulation, thereby eliminating redundant facilities and reducing space requirements
Solution Approach 2:
The patent introduces a reversal mechanism that inverts the orientation of the cell module assembly halfway through the circular logistics flow. This inversion allows the assembly to be stacked efficiently in multiple layers while maintaining the unidirectional circular flow, solving the adaptability issue for stacked battery modules without requiring additional facilities
2Productivity
If conventional unidirectional logistics flow is used for battery module assembly, then existing assembly line facilities can be applied, but equipment layout length and area increase
Solution Approach 1:
The patent transitions from a linear unidirectional logistics flow to a two-dimensional circular logistics flow. By arranging the facility lines in a closed loop configuration and introducing vertical stacking through the reversal mechanism, the system maximizes space utilization in both horizontal and vertical dimensions, significantly reducing the overall equipment layout area while maintaining manufacturing efficiency
3Ease of manufacture
If two facilities with the same concept are required for stacked battery module, then manufacturing capability is achieved, but redundant facility investment increases
Solution Approach 1:
The patent designs the circular logistics flow system to perform multiple functions within a single integrated facility. The same circular flow accommodates different assembly operations (cell housing, electric connection, series connection) at different stages, and the reversal mechanism enables the system to handle stacked module configurations. This multi-functionality eliminates the need for separate duplicate facilities
Data Source
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AI summary
Disclosed is an assembly line system of a stacked battery module, which includes a first facility line configured to assemble a cell housing and accommodate battery cells in the cell housing; a second facility line configured to assemble an electric connection component and a voltage sensing component; and a third facility line configured to connect the battery cells to each other in series and in parallel and to inspect functional abnormality thereof, wherein the first facility line, the second facility line and the third facility line are arranged to circulate in order based on a predetermined origin, and a first-layer cell module assembly assembled at a first circulation is reversed to change the top and bottom thereof so that a second-layer cell module assembly is assembled on the first-layer cell module assembly at a second circulation.