Battery Module Guide Holder Layout for Tolerance-Tolerant Assembly
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Solution Overview
Problem
The assembly of battery modules is challenging due to the need to align multiple battery cells accurately, which is complicated by machining errors and tolerance accumulation, leading to difficulty in assembly efficiency and quality.
Innovation Solution
The use of holders with guide portions of gradually decreasing lengths that provide guidance and support for battery units, allowing for layered mounting without simultaneous alignment of all cells, reducing the impact of tolerance errors and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If all battery cells are required to be aligned simultaneously with mounting positions on the holder, then positioning precision is improved, but assembly complexity and difficulty increase significantly
Solution Approach 1:
The guide structure is divided into multiple guide portions with different extension lengths in the first direction. Each guide portion corresponds to a battery unit and provides independent guidance, allowing sequential assembly rather than requiring simultaneous alignment of all cells. This segmentation reduces assembly complexity while maintaining positioning precision through the graduated extension lengths.
2Quantity of substance
If the number of battery cells is large, then energy density is improved, but assembly difficulty increases due to tolerance accumulation
Solution Approach 1:
By dividing the guide structure into multiple guide portions with progressively decreasing extension lengths, each corresponding to a battery unit, the system enables sequential assembly of large numbers of cells without requiring complex simultaneous alignment. This reduces the impact of tolerance accumulation.
Solution Approach 2:
The guide portions extend in the third direction with varying lengths in the first direction, creating a three-dimensional graduated structure. This dimensional approach allows cells to be guided and positioned sequentially as holders are brought together, simplifying the assembly of large numbers of cells.
3Ease of manufacture
If guide portions have uniform extension lengths, then manufacturing simplicity is improved, but guidance effectiveness during layered mounting deteriorates
Solution Approach 1:
The guide portions are designed with asymmetric, graduated extension lengths in the first direction, where each subsequent guide portion extends less than the previous one. This asymmetric design provides effective guidance during layered mounting by creating a tapered path that facilitates sequential assembly, while remaining manufacturable through standard machining processes.
Data Source
AI summary
A battery module includes a plurality of battery units arranged in a first direction and each including a plurality of battery cells arranged in a second direction perpendicular to the first direction, and two holders respectively located at two ends of the plurality of battery units in a third direction perpendicular to the second direction and the first direction. Each of the holders includes a main body portion. A plurality of guide portions are provided on a side of the main body portion close to the plurality of battery units, and are arranged corresponding to the plurality of battery units. The guide portions extend toward the plurality of battery units in the third direction, and are configured to provide guidance for movement of the corresponding battery cells. Extension lengths of the plurality of guide portions gradually decrease in the first direction.