Battery Pack Guide Jig for Spring-Back Edge Alignment
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Solution Overview
Problem
The conventional assembly process of battery pack case trays and case covers often experiences inefficiencies and product defects due to the spring back phenomenon, making it difficult for the edges to face each other correctly during coupling.
Innovation Solution
A battery pack assembly guide jig is designed to support the case tray and case cover by using first and second guiding units with insertion portions to temporarily fix the edges, preventing the spring back and ensuring accurate alignment and coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the case tray and case cover are assembled using conventional fastening methods, then the assembly process is simple, but the spring back phenomenon causes edges to misalign and assembly precision deteriorates
Solution Approach 1:
The guide jig is assembled beforehand and positioned on the case tray before the case cover is installed. The guiding units with insertion portions are prepared in advance to receive the protruding portions of the case cover, ensuring that when the case cover is placed, the edges are automatically aligned with high precision without spring back misalignment.
Solution Approach 2:
The guide jig acts as an intermediary tool between the case tray and case cover during assembly. The guiding units with insertion portions receive the protruding portions of the case cover, mediating the alignment process and preventing edge misalignment caused by spring back phenomenon, thereby improving edge alignment precision while maintaining assembly simplicity.
2Productivity
If the case tray and case cover are assembled without guidance, then the assembly process is fast, but product defects increase due to erroneous assembly
Solution Approach 1:
The guide jig serves as an intermediary device that guides the case cover during assembly. The guiding units with insertion portions receive the protruding portions of the case cover, ensuring correct positioning and preventing erroneous assembly. This maintains high assembly speed while significantly improving assembly correctness by providing physical guidance throughout the process.
Solution Approach 2:
The guide jig is prepared and positioned on the case tray before the case cover is installed. The guiding units are readied in advance to guide the protruding portions of the case cover into correct positions, ensuring assembly correctness is maintained throughout the fast assembly process without requiring post-assembly adjustments.
3Manufacturing precision
If guiding units with insertion portions are used to fix the edges, then edge alignment precision is improved, but device complexity increases
Solution Approach 1:
The guide jig is divided into multiple guiding units, each with its own insertion portions. This segmentation allows each guiding unit to independently handle the alignment of specific edges or corners, achieving high edge alignment precision across the entire case cover while keeping each individual guiding unit relatively simple in structure.
Solution Approach 2:
The guide jig is designed with multiple guiding units that can guide different edges and corners of the case cover using the same insertion portion mechanism. This multi-functionality allows a single standardized guiding unit design to handle multiple alignment tasks, improving edge alignment precision without proportionally increasing overall device complexity.
Data Source
AI summary
A battery pack assembly guide jig for guiding an assembly of a battery pack having a case tray and a case cover is provided. The battery pack assembly jig includes a first guide configured to temporarily fix a first side edge of the case tray and a first side edge of the case cover, and a second guide spaced apart from the first guide by a predetermined distance and configured to temporarily fix a second side edge of the case tray opposite the first side edge of the case tray and a second side edge of the case cover opposite the first side edge of the case cover. The battery pack assembly guide jig is configured to support the case tray and the case cover of the battery pack when the case tray and the case cover are coupled to each other.