Battery Module Alignment Inspection Using Moving Depth Gauges
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Solution Overview
Problem
Current methods for inspecting the alignment of battery cells in a battery module are inadequate, as they either cause damage due to contact inspections or fail to accurately measure alignment due to non-contact methods, especially when cells are not properly aligned during stacking, affecting cooling and insulation performance.
Innovation Solution
A system with a wheel interface between the inspection jig and battery module, using a gauge assembly with digital depth gauges that move along rails to sense the depth of each battery cell, preventing slip and damage, and allowing for automated inspection within production line time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact inspection is used to measure alignment of battery cells, then measurement precision is improved, but the battery cells may be damaged due to rubbing friction with the inspection jig
Solution Approach 1:
A sheet of paper is introduced as an intermediary material between the inspection jig and the battery cells. The inspection jig pushes the paper against the lower surfaces of the battery cells, allowing the gauge to measure alignment through the paper without direct contact between the jig and cells, thus preventing insulation damage while maintaining measurement capability
Solution Approach 2:
The inspection method replaces direct mechanical contact measurement with a paper-mediated measurement system. Instead of the inspection jig directly touching and potentially damaging the battery cells, the gauge measures alignment by pushing paper against the cells, substituting the harmful mechanical contact with a gentler intermediary mechanism
2Object-affected harmful factors
If non-contact inspection using laser distance measurement sensor is used, then damage to battery cells is prevented, but measurement precision deteriorates due to springback of pushed portions
Solution Approach 1:
Paper serves as an intermediary that transmits force from the inspection jig to the battery cells without causing damage. The gauge pushes the paper, which in turn contacts the battery cells, allowing accurate measurement of alignment while preventing direct mechanical damage that would cause springback errors
Solution Approach 2:
The inspection is performed at a predetermined timing point during the stacking process, before the battery cells are fully compressed and before springback occurs. This preliminary measurement captures the alignment state when cells are still in their pushed position, providing accurate data before the springback phenomenon distorts the measurement
3Measurement precision
If inspection is performed after stacking process, then all battery cells can be inspected, but process time increases and production efficiency decreases
Solution Approach 1:
The alignment inspection is integrated into the stacking process itself, performed at a predetermined timing point during stacking rather than after completion. This preliminary inspection allows alignment verification to occur concurrently with the stacking operation, eliminating separate inspection time and maintaining production efficiency
Solution Approach 2:
The inspection process is merged with the stacking process by performing alignment measurement at a specific timing point during stacking. The gauge assembly operates in coordination with the stacking mechanism, combining two operations into one integrated process that achieves both stacking and inspection without additional time loss
4Measurement precision
If inspection jig is inserted into gap space between jig and lower portion of battery module, then alignment can be measured, but only cells sagging downward can be inspected and inner cells concentration cannot be detected
Solution Approach 1:
The measurement approach transitions from horizontal insertion of an inspection jig into gap spaces to a vertical measurement dimension. The gauge assembly moves vertically downward to push paper against the lower surfaces of battery cells, enabling measurement of alignment in the vertical dimension regardless of horizontal cell distribution or concentration patterns
Data Source
AI summary
An exemplary embodiment of the present disclosure provides a system for inspecting a degree of alignment of a battery module, which inspects an aligned state of a battery cell in a battery module configured by assembling a plurality of battery cells, the system including: an alignment degree inspection table having an opening and configured such that the battery module is seated along an edge of the opening; and a gauge assembly configured to sense a degree of alignment of each of the battery cells disposed at a lower side of the battery module and exposed through the opening, in which the gauge assembly senses a depth of the battery cell while moving in a longitudinal direction of the inspection table.