Battery Module Welding Head With Multi-Axis Positioning
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Solution Overview
Problem
Existing apparatuses for assembling battery cells or modules with electrical terminals are not constructively simple, efficient, or adaptable to different configurations, and lack effective quality control and rapid commissioning/installation capabilities.
Innovation Solution
A welding apparatus with a tool that moves along multiple axes to position and hold battery cells or modules for precise welding, featuring a welding head that can operate remotely and oscillate, along with thermal cameras for quality control, and quick-coupling systems for easy setup and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex apparatus structure is used to assemble battery cells, then welding precision can be improved, but device complexity and ease of manufacture worsen
Solution Approach 1:
The apparatus is divided into independent modular units: a movable tool assembly with positioning capabilities and a separate welding head. This segmentation allows each module to be optimized independently for its specific function while simplifying the overall system architecture and ease of manufacture.
Solution Approach 2:
The tool assembly is designed with multi-functionality, capable of performing both positioning and bending operations on battery terminals before welding. This universal tool reduces the need for separate dedicated devices for each operation, simplifying the overall apparatus structure while maintaining welding precision.
2Stability of the object's composition
If a fixed welding apparatus is used, then structural stability is improved, but adaptability to different battery configurations worsens
Solution Approach 1:
The tool assembly incorporates movable components that can dynamically adjust their position and orientation along multiple axes. This dynamic capability allows the apparatus to adapt to various battery cell configurations and terminal positions while maintaining structural stability during the welding process through controlled positioning.
Solution Approach 2:
The apparatus allows for parameter changes in the positioning system, enabling adjustment of the tool's coordinates and orientation to match different battery configurations. This flexibility in parameter adjustment provides adaptability to various applications while preserving structural stability during operation.
3Ease of operation
If multiple separate operations are used for positioning and welding, then operational simplicity is improved, but productivity worsens
Solution Approach 1:
The positioning tool and welding head are merged into a single integrated assembly that can perform positioning, bending, and welding operations in sequence without requiring separate handling or repositioning of components. This merging eliminates intermediate steps and improves productivity while maintaining operational simplicity through unified control.
Solution Approach 2:
The tool assembly performs preliminary positioning and bending actions on the battery terminals before the welding operation begins. This preliminary action ensures that all preparatory steps are completed while the components are already in position, eliminating the need for additional repositioning operations and thereby improving assembly speed and productivity.
4Productivity
If the welding head is positioned close to the elements, then welding efficiency is improved, but accessibility and remote operation capability worsen
Solution Approach 1:
The welding head is positioned in a remote location relative to the battery cells, utilizing spatial dimensionality to achieve welding through the thickness of the cell structure. This dimensional approach allows the welding head to operate from a remote position while maintaining welding efficiency by directing energy through the material, thereby enabling remote operation capability without sacrificing productivity.
Data Source
AI summary
An apparatus for assembling battery cells or battery modules together each having electrical terminals that must be subjected to a welding operation. The apparatus includes a tool for engaging and holding the battery cells or the battery modules to be welded, which can be moved along at least two axes to carry and maintain one or more battery cells or battery modules in a configuration r position suitable for welding the electrical terminals to at least one of respective electrical connecting elements or welding said electrical terminals to each other. The apparatus also includes a welding head carried by said tool and arranged to perform welding operations on the electrical terminals to be welded.