Battery Module Force Measurement for Assembly Load Profiling
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Solution Overview
Problem
Current methods for measuring forces during the installation of battery modules into battery housings are time-consuming and do not allow for the measurement of chronological force profiles, leading to incomplete data on assembly forces.
Innovation Solution
A force measurement module with a housing matching the external dimensions of the battery module, equipped with force sensors that measure forces during installation, allowing for the capture of chronological force profiles. This module can be pressed into a battery compartment and measures forces accurately, replacing the actual battery module during the initial pressing and screwing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure measurement foils are used to measure total forces during pressing and screwing, then force measurement is possible, but chronological force profiles cannot be captured and evaluation is time-consuming
Solution Approach 1:
The patent replaces the passive mechanical pressure measurement foil with an active electronic force sensor system. The force sensor electronically captures chronological force profiles during pressing and screwing operations, eliminating the need for manual evaluation of discoloration patterns on pressure foils. This substitution enables real-time digital recording and analysis of force data.
Solution Approach 2:
The patent introduces a housing as an intermediary component between the force sensor and the battery module. The housing transfers assembly forces to the force sensor during pressing and screwing operations, enabling indirect measurement of forces that would otherwise be difficult to capture chronologically. This intermediary structure facilitates the use of electronic sensors in the assembly process.
2Measurement precision
If pressure measurement foils are used, then total forces are measurable, but chronological force profiles during pressing or screwing cannot be measured
Solution Approach 1:
The patent replaces the static pressure measurement foil with a dynamic electronic force sensor system that continuously records force data throughout the assembly process. This electronic system captures chronological force profiles during pressing and screwing operations, preserving temporal information that the static foil cannot record.
Solution Approach 2:
The patent positions the force sensor and housing in place before the actual assembly operation begins. This preliminary setup ensures that the sensor is ready to capture chronological force profiles from the start of pressing or screwing operations, enabling complete temporal recording of the assembly process.
3Loss of information
If force measurement module is used, then chronological force profiles can be measured, but device complexity increases compared to pressure measurement foils
Solution Approach 1:
The housing serves multiple functions: it provides structural support for the force sensor, acts as an intermediary to transfer assembly forces to the sensor, and enables chronological force profile measurement. This multi-functionality reduces the need for separate specialized components, thereby managing complexity while achieving comprehensive force measurement capability.
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
The force measurement module provides accurate and detailed force measurements, allowing for precise determination of assembly forces and reducing internal stresses in battery cells, thereby extending the service life of the battery module.
Implementation Method 1
at least one force sensor which is arranged in the housing and is designed to determine a force when installing the housing into the battery housing
Data Source
AI summary
A force measurement module for determining of a force when installing a battery module into a battery housing includes a housing having a shape and external dimensions substantially of the battery module and at least one force sensor arranged in the housing. The at least one force sensor is configured to determine a force when installing the housing into the battery housing. Furthermore, a method for determining a force when installing a battery module into a battery housing is provided.