Battery Pack Bottom Connection Tray for Automated Assembly
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Solution Overview
Problem
The existing assembly process for battery packs in electric vehicles is inefficient and unreliable, requiring manual connection of battery modules and wire harnesses, which hinders automated assembly and production.
Innovation Solution
A battery pack with a bottom connection type tray featuring protruding tray terminals and embedded connection wires, allowing for automated assembly by connecting battery modules to tray terminals using male and female connectors, enabling efficient and reliable terminal connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual connection of battery modules and wire harnesses is used, then assembly flexibility is maintained, but assembly efficiency and productivity are reduced
Solution Approach 1:
The connection terminals are pre-installed on the tray bottom plate before battery modules are loaded. This preliminary action allows automated systems to simply place battery modules onto predetermined positions, where connections are automatically established through the pre-positioned terminals, eliminating manual wiring operations and enabling automated assembly
Solution Approach 2:
The tray bottom plate serves as an intermediary structure that integrates both mechanical support and electrical connection functions. By incorporating connection terminals directly into the tray bottom plate, it mediates between the battery modules and the electrical system, allowing automated placement while ensuring reliable electrical connections
2Reliability
If manual connection of battery modules is used, then assembly adaptability is maintained, but connection reliability is reduced
Solution Approach 1:
The invention merges the support function and electrical connection function into a single integrated structure - the tray bottom plate with embedded terminals. This consolidation ensures that mechanical placement automatically establishes reliable electrical connections, eliminating the separate manual connection step and improving both reliability and manufacturing ease
Solution Approach 2:
The tray bottom plate with pre-installed terminals enables the assembly process to be self-servicing. When battery modules are placed on the tray, the connections are automatically established without requiring additional manual operations, thereby improving connection reliability while simplifying the manufacturing process
3Device complexity
If traditional wire harness connection is used, then design flexibility is maintained, but manufacturing complexity is increased
Solution Approach 1:
The invention extracts the electrical connection function from the traditional wire harness system and integrates it directly into the tray bottom plate. This extraction eliminates the need for separate wire harness routing and manual connection operations, reducing assembly structure complexity while easing the manufacturing process
Data Source
AI summary
A battery pack having a bottom connection type tray is provided. The battery pack includes a tray configured to load a plurality of battery modules therein, a plurality of tray terminals provided on a bottom plate of the tray, a connection wire for interconnecting the tray terminals or connecting the tray terminals to an external circuit, and a battery terminal provided in each of the battery modules to be connected to a corresponding one of the tray terminals. Terminal connection is achieved while the battery modules are assembled with the tray, and therefore, an assembly procedure is more easily performed, and the reliability of a terminal connection structure is improved. In addition, automated assembly and production using a robot are possible.