Traction Battery Pack Assembly With Adjustable Cell Opening
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Solution Overview
Problem
Conventional traction battery pack assembly methods require complex array support structures and inefficient cell stacking due to fixed enclosure sizes, limiting flexibility and efficiency in assembling high-voltage battery packs for electrified vehicles.
Innovation Solution
A method involving a manufacturing equipment system that engages and disengages with an enclosure structure to adjust the cell-receiving opening size, compresses cell stacks, and uses wedge portions to facilitate perpendicular insertion and secure the cell stacks within a metal or metal-alloy enclosure tray, eliminating the need for array support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fixed-size enclosure structures are used, then manufacturing simplicity is maintained, but assembly flexibility and efficiency are reduced
Solution Approach 1:
The enclosure structure incorporates a cell-receiving opening that can dynamically change size through manufacturing equipment engagement. The opening is adjusted from a first size to a second size to accommodate cell stacks of varying dimensions, enabling flexible assembly while maintaining a relatively simple enclosure design without complex support structures.
Solution Approach 2:
The size parameter of the cell-receiving opening is changed during the assembly process. The opening transitions between different size states (first size and second size) to match the dimensions of cell stacks being assembled, providing adaptability without requiring multiple fixed-size enclosures or complex support frameworks.
2Productivity
If array support structures are used, then structural stability is improved, but device complexity and assembly efficiency are reduced
Solution Approach 1:
The patent eliminates array support structures from the enclosure design. By removing these intermediate support components, the assembly process is simplified and efficiency is improved, while the enclosure structure itself is designed to directly accommodate cell stacks through adjustable opening sizes.
Solution Approach 2:
The functions of support structures and enclosure boundaries are merged into a single integrated enclosure structure. The cell-receiving opening serves both as the boundary definition and as the direct interface for cell stack insertion, eliminating the need for separate support structures.
3Manufacturing precision
If cell stacks are inserted without size adjustment, then assembly speed is maintained, but packing density and structural optimization are reduced
Solution Approach 1:
The size of the cell-receiving opening is adjusted preliminarily before cell stack insertion. The opening is set to the appropriate second size that matches the cell stack dimensions, ensuring optimal packing density from the start of insertion without requiring post-adjustment or repositioning that would slow assembly.
Solution Approach 2:
The enclosure structure dynamically adapts its opening size to match the specific cell stack being inserted. This dynamic adjustment ensures that each cell stack is received at the optimal size configuration, maximizing packing density while maintaining smooth assembly flow without forced fits or adjustments during insertion.
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
This method enables efficient and flexible assembly of traction battery packs by allowing for the direct insertion and compression of cell stacks within an enclosure, reducing the need for additional support structures and enhancing the packing density and electrical bussing arrangement.
Implementation Method 1
changing a size of a cell-receiving opening in the enclosure structure using the manufacturing equipment
Implementation Method 2
the enclosure structure compressing the at least one cell stack
Implementation Method 3
compressing the at least one cell stack with the enclosure structure
Data Source
AI summary
A battery pack assembly method includes engaging an enclosure structure with manufacturing equipment, changing a size of a cell-receiving opening in the enclosure structure using the manufacturing equipment, inserting at least one cell stack into the cell-receiving opening, and disengaging the manufacturing equipment from the enclosure structure.