Battery Pack Guide Rail Assembly for Compact Module Insertion
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Solution Overview
Problem
The existing battery pack manufacturing process is inefficient and prone to damage due to collisions between the battery module and the outer housing during assembly, leading to increased costs and potential failures during use, especially in applications exposed to external impacts or vibrations.
Innovation Solution
The battery pack design incorporates guide rails and protrusions within the pack housing and module case to facilitate precise alignment and secure insertion, along with a bumper portion to absorb external impacts, enhancing durability and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery module is inserted into the narrow internal space of the outer housing, then the battery pack structure is compact, but collision between the battery module and outer housing occurs causing damage
Solution Approach 1:
Guide rails are introduced as intermediary components between the battery module and outer housing. These guide rails provide a controlled insertion path that prevents direct collision with the housing walls, enabling the battery module to be inserted into the compact space without damage.
Solution Approach 2:
The guide rails are pre-installed on the inner surface of the outer housing before battery module insertion. This preliminary arrangement ensures that the insertion path is prepared in advance, guiding the battery module smoothly into position without requiring adjustment during the insertion process.
2Ease of manufacture
If there is a gap between the battery module and outer housing after assembly, then insertion is easier, but frequent friction or collisions occur during use causing damage to internal components
Solution Approach 1:
The guide protrusion portions are strategically positioned at specific locations on the battery module case to provide localized guidance and positioning. This ensures that the battery module is held firmly in the correct position without requiring a complete gapless fit, balancing assembly ease with operational reliability.
Solution Approach 2:
The guide rails and guide protrusions are designed to automatically align and position the battery module during insertion, preliminarily establishing the correct position before final assembly. This preliminary positioning prevents excessive gaps that would lead to collisions during vehicle operation.
3Manufacturing precision
If the insertion process is difficult and time-consuming, then manufacturing precision may be improved, but manufacturing cost increases
Solution Approach 1:
The guide rails and guide protrusions form a self-aligning mechanism that automatically guides the battery module into the correct position during insertion. This self-service feature eliminates the need for manual alignment adjustments by operators, maintaining high precision while improving assembly speed and reducing labor requirements.
Solution Approach 2:
The guiding features are pre-configured on both the outer housing and battery module, so that alignment is automatically achieved during the insertion process itself. This preliminary configuration of guiding elements ensures that precision is built into the design rather than requiring time-consuming post-assembly adjustments.
Data Source
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AI summary
A battery pack according to the present disclosure includes a battery module including a plurality of secondary batteries and a module case having an outer wall configured to form an internal space for receiving the plurality of secondary batteries, and a pack housing including an intermediate housing having an outer sidewall configured to form an internal space for receiving the module case, wherein at least one guide rail is provided on an inner surface of the intermediate housing, the guide rail protruding in an inward direction toward the battery module and extending in a vertical direction to guide the insertion of the module case in the vertical direction, and at least one guide protrusion portion is provided on an outer surface of a horizontal direction of the module case, the guide protrusion portion protruding in an outward direction and extending in the vertical direction to move in the vertical direction along the guide rail, and having at least one compression protrusion protruding to press the guide rail.