Battery Module Clamping Assembly for Tolerance-Tolerant Fixation
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Solution Overview
Problem
Long battery modules in electric vehicles face challenges in rigid fixation due to increased tolerance chains and complexity in aligning multiple fixation points, requiring efficient and reliable assembly solutions that minimize alignment errors.
Innovation Solution
A battery module assembly featuring a module-receiving compartment with support elements and threaded fixation elements that allow for clamping engagement of battery modules without the need for exact alignment, reducing tolerance chains and enabling flexible positioning of threaded through-holes across the module's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fixation holes and bolts are used to ensure rigid fixation of long battery modules, then the fixation reliability is improved, but the manufacturing complexity and tolerance chain increase
Solution Approach 1:
The fixation system is segmented into a C-shaped clamp body with integrated fixation points distributed along its length. This allows multiple fixation holes to be used without creating a complex tolerance chain, as each fixation point operates independently within the segmented structure.
Solution Approach 2:
Multiple fixation functions are merged into a single C-shaped clamp body. The clamp integrates multiple fixation holes and bolt attachment points into one unified component, eliminating the need for separate fixation elements and reducing manufacturing complexity while maintaining reliable fixation.
2Reliability
If multiple fixation holes are used to secure long battery modules, then the fixation reliability is improved, but the alignment precision requirements increase
Solution Approach 1:
The clamp body is segmented with multiple fixation holes positioned at different locations along its length. This segmentation allows each hole to be positioned with reasonable precision independently, rather than requiring all holes to align perfectly with corresponding holes in the battery module.
Solution Approach 2:
The C-shaped clamp body acts as an intermediary element between the battery module and the mounting structure. It distributes the fixation requirements across multiple points along its curved structure, reducing the alignment precision requirements compared to direct point-to-point fixation.
3Strength
If traditional fixation methods with multiple bolts and holes are used, then the fixation strength is improved, but the assembly time increases
Solution Approach 1:
Multiple fixation operations are merged into a single assembly action. The C-shaped clamp body with its integrated fixation holes allows all fixation points to be engaged simultaneously, reducing assembly time while maintaining the strength benefits of multiple fixation points.
Solution Approach 2:
The clamp body is pre-configured with fixation holes positioned and oriented correctly during manufacturing. This preliminary action eliminates the need for complex alignment procedures during assembly, allowing rapid installation while maintaining strong fixation.
Data Source
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AI summary
A battery module assembly (3) for an electrically powered machine (4), the battery module assembly (3) comprising a module-receiving compartment (1) and a battery module (2) accommodated in the module-receiving compartment (1), wherein the module-receiving compartment (1) comprises threaded fixation elements (16) extending in threaded engagement through at least part of a plurality of through-holes (14), each fixation element (16) having an abutment end (18) configured to abut and engage a respective part of the battery module (2) accommodated in the module-receiving compartment (1), the fixation elements (16) being configured to fix the battery module (2) in clamping engagement between the at least a first and a second support elements (10, 12), the battery module (2) being fixed between the first and second support elements (10, 12) solely by the abutment ends (18) of the fixation elements (16).