Battery Module Sheath Assembly Using Compression Jaws
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Solution Overview
Problem
The existing assembly methods for electric vehicle battery modules are complex and time-consuming, requiring welding of metal retaining plates around cell assemblies, which complicates the process and increases costs while ensuring mechanical strength and watertightness.
Innovation Solution
A method involving a handling device with movable jaws and a housing element to compress and secure electrochemical cells within a sheath, allowing for efficient assembly and fixation of holding plates, with optional welding, ensuring mechanical strength and watertightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal retaining plates are welded around cell assemblies to ensure mechanical strength and watertightness, then the structural integrity is improved, but the assembly complexity and production time increase
Solution Approach 1:
The handling device is divided into separate functional components: a body portion and movable jaws. This segmentation allows the jaws to be independently positioned and operated to apply compression forces, simplifying the overall assembly process while maintaining structural integrity through controlled compression rather than complex welding operations.
Solution Approach 2:
The handling device acts as an intermediary tool that facilitates the assembly of holding plates and cells without requiring direct welding operations. By using the jaws to compress and secure components in place, the device mediates between the need for strong mechanical bonds and the desire to simplify the assembly process, reducing both complexity and production time.
2Reliability
If metal retaining plates are welded around cell assemblies to ensure watertightness, then the sealing performance is improved, but the production time increases
Solution Approach 1:
The holding plates are pre-positioned around the cell assemblies before final securing operations. The handling device with movable jaws applies compression forces to hold these plates in their correct positions, ensuring proper alignment and sealing surfaces are established beforehand. This preliminary positioning action reduces the time required for final welding or securing operations while maintaining watertight integrity.
3Strength
If cells are immobilized for welding operations to ensure mechanical strength, then the structural integrity is improved, but the assembly time increases
Solution Approach 1:
The handling device employs movable jaws that can dynamically adjust their position and apply controlled compression forces during the assembly process. This dynamic capability allows for rapid immobilization of cells in the correct positions without requiring time-consuming fixed tooling or complex welding fixtures, thereby improving assembly speed while maintaining the mechanical strength needed for proper cell bonding.
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
Facilitates assembly operations, reducing costs while maintaining mechanical strength and watertightness of the battery module, enabling efficient production of a sealed module.
Implementation Method 1
the two jaws applying compressive forces along the first axis respectively on the first holding plate and on the second holding plate, the assembly being in a contracted configuration along the first axis
Data Source
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AI summary
A method of assembling a module for an electric battery comprising the steps of: - obtaining an assembly successively comprising a first holding plate, a plurality of electrochemical cells, and a second holding plate, - obtaining a housing element forming a sheath, - obtaining a handling device comprising a body, and two jaws movable relative to each other along a compression axis, one of the two jaws and a portion of the body forming an elongated part of the handling device extending along the compression axis on one side of a receiving zone, - moving the housing element to place the housing element in the receiving zone, then towards an intermediate position, in which the housing element surrounds the elongated part, - moving the assembly to place the assembly in the receiving zone,and moving the two jaws to apply compressive forces to the first holding plate and the second holding plate, the assembly being in a contracted configuration, - installing electrical connectors between at least some of the cells, - moving the housing element from the intermediate position to a threaded position, in which the sheath surrounds the assembly, - fixing the first holding plate and the second holding plate respectively on the housing element, - moving the two jaws to release the assembly and the housing element.,