Battery Pack Bus Bar Welding for Misaligned Cell Terminals
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Solution Overview
Problem
The assembly process of battery packs often requires frequent correction work due to the non-straight distribution of cell terminals, which increases productivity issues.
Innovation Solution
A battery pack manufacturing method that involves stacking battery cells, pressurizing the cell group, measuring cell terminal positions, finding a center straight line through the terminal distribution, and using this line to position a welding jig for pressing and welding the bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cell terminals are distributed along a non-straight line, then the battery pack can accommodate varying terminal positions, but the pressing position of the bus bar becomes greatly distanced from the cell terminal position, requiring frequent correction work
Solution Approach 1:
The patent measures the positions of all cell terminals before the welding process and calculates the center straight line in advance. This preliminary measurement and calculation enable the welding jig to be positioned accurately before actual welding begins, preventing the need for frequent correction work during the assembly process.
Solution Approach 2:
The patent uses measured position data of cell terminals to feedback into the positioning system. The center straight line is calculated based on actual measured positions, and this information is used to adjust and position the welding jig accordingly, creating a closed-loop system that adapts to actual variations in terminal positions.
2Adaptability or versatility
If cell terminals are distributed along a non-straight line, then the battery pack can accommodate varying terminal positions, but the welding precision decreases due to increased distance between bus bar pressing position and cell terminal position
Solution Approach 1:
The patent measures the positions of all cell terminals before the welding process and calculates the center straight line in advance. This preliminary measurement and calculation enable the welding jig to be positioned accurately before actual welding begins, preventing the need for frequent correction work during the assembly process.
Solution Approach 2:
The patent uses measured position data of cell terminals to feedback into the positioning system. The center straight line is calculated based on actual measured positions, and this information is used to adjust and position the welding jig accordingly, creating a closed-loop system that adapts to actual variations in terminal positions.
Data Source
AI summary
A battery pack manufacturing method according to an aspect of the present disclosure includes stacking battery cells, pressurizing a battery cell group provided by stacking the battery cells in a stacking direction, measuring positions of cell terminals of the battery cells included in the pressurized battery cell group, finding a center straight line passing through a center of a distribution of the positions of the cell terminals, positioning a welding jig configured to decide a position where a bus bar is pressed against at least one of the cell terminals with reference to the center straight line, and welding the bus bar that is pressed against the at least one of the cell terminals, to the at least one of the cell terminals by the welding jig.