Battery Module Insertion Mechanism for Low-Defect Pack Assembly
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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 with a frame and moving unit to automate the insertion of battery modules into pack housings, along with an attaching and detaching mechanism using clamps and a feeding mechanism with a conveyor to streamline the process and prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of battery modules is used, then flexibility and simplicity are maintained, but manufacturing efficiency decreases and defect rate increases
Solution Approach 1:
The battery module insertion apparatus is designed to perform the insertion operation automatically without requiring manual intervention. The apparatus includes a gripping unit that automatically grasps the battery module, a moving unit that transports it, and a positioning mechanism that aligns it with the pack housing, enabling the system to serve itself in completing the insertion task
Solution Approach 2:
The patent replaces manual mechanical handling with an automated mechanical system consisting of a gripping unit with clamps, a moving unit with drive mechanisms, and a positioning system. This substitution of manual operations with automated mechanical components increases productivity while managing complexity through systematic design
2Reliability
If manual insertion of battery module is performed, then equipment cost is reduced, but manufacturing defect rate increases due to potential shocks and short circuits
Solution Approach 1:
The apparatus incorporates protective mechanisms that cushion and protect the battery module during the insertion process. The controlled movement and positioning systems prevent shocks and impacts that could cause defects, while the automated handling avoids human error that leads to short circuits
Solution Approach 2:
By replacing manual handling with a controlled automated mechanical system, the patent eliminates human error in the insertion process. The automated apparatus ensures consistent, shock-free insertion that prevents manufacturing defects while the systematic design manages the complexity of the replacement system
3Productivity
If automated lifting mechanism is introduced, then manufacturing efficiency improves, but device complexity increases
Solution Approach 1:
The automated lifting mechanism is divided into distinct functional units: a gripping unit for securing the battery module, a moving unit for transportation, and a positioning mechanism for alignment. This segmentation allows each component to perform its specific function efficiently while reducing overall system complexity through modular design
Solution Approach 2:
The lifting mechanism is designed with multi-functional components that perform multiple operations. The gripping unit not only secures the battery module but also facilitates its transfer and positioning, reducing the need for separate dedicated components and thereby managing complexity while maintaining high assembly efficiency
Data Source
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AI summary
Disclosed 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.