Battery Module Insertion Assembly for Low-Defect Pack Housing Fit
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Solution Overview
Problem
Conventional battery pack manufacturing methods are inefficient and prone to defects due to manual handling of heavy battery modules, leading to potential shocks, short circuits, and increased manufacturing costs.
Innovation Solution
A battery pack manufacturing apparatus featuring a lifting mechanism, module support, and attaching/detaching mechanism with clamps and a feeding conveyor system to automate the insertion and fixation of battery modules into pack housings, including an erroneous insertion detection unit to ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual handling of battery modules is used, then device complexity is reduced, but manufacturing precision deteriorates due to potential shocks and short circuits
Solution Approach 1:
The patent replaces manual mechanical handling with an automated lifting mechanism that uses a moving unit to vertically transport the battery module into the pack housing. This automated mechanical system eliminates human error and potential shocks associated with manual handling, thereby improving manufacturing precision while maintaining relatively simple device complexity.
2Manufacturing precision
If automated lifting mechanism is introduced, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The lifting mechanism is segmented into distinct functional components: a frame structure, a moving unit for vertical motion, and a module support for holding the battery module. This segmentation allows each component to perform its specific function efficiently while keeping the overall design manageable and not excessively complex.
Solution Approach 2:
The frame structure serves multiple functions: it supports the moving unit, holds the pack housing, and provides structural stability. The module support both holds the battery module during lifting and positions it for insertion. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
3Productivity
If automated insertion process is used, then productivity is improved, but device complexity increases
Solution Approach 1:
The moving unit provides dynamic vertical motion to the module support, enabling the battery module to be lifted and inserted into the pack housing automatically. This dynamic capability allows the system to adapt to different insertion depths and positions, improving productivity while keeping the mechanism relatively simple through controlled motion rather than complex multi-axis positioning.
4Device complexity
If manual handling is used, then device complexity is reduced, but reliability deteriorates due to potential shocks and short circuits
Solution Approach 1:
The automated lifting mechanism replaces manual handling operations, eliminating the risk of human error such as dropping the battery module or causing shocks during insertion. The controlled vertical motion ensures reliable and damage-free assembly, significantly improving battery module assembly reliability.
Solution Approach 2:
The lifting mechanism is designed to control the motion and positioning of the battery module throughout the insertion process, preventing shocks and impacts before they can occur. The system ensures smooth, controlled movement and precise positioning, cushioning against potential damage beforehand rather than reacting to it afterward.
Data Source
AI summary
Discussed is a battery pack manufacturing apparatus and method, and more particularly, a battery pack manufacturing apparatus allowing automatic production and having a minimized manufacturing defect rate. The battery pack manufacturing apparatus manufactures a battery pack having a pack housing and a battery module, and includes a lifting mechanism having a frame configured to mount the pack housing and a moving unit configured to move the frame so that the battery module is inserted into an inner space of the pack housing; and a module support configured to support the battery module.